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NATIONAL ALUMINIUM COMPANY LIMITED SMELTER PLANT, NALCONAGAR ANGUL, ORISSA
SMELTER DIVISION
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SPECIFICATION FOR ADDITIONAL LIQUID PITCH HANDLING STORAGE, UNLOADING & TRANSFER FACILITIES (GREEN ANODE PLANT, CARBON AREA) ISSUE NO 01
SMELTER DIVISION
REVISION 01
ISSUE DATE 01.12.2007
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CONTENTS Sl. No. 1. 2. 3. 4. 4. 5.
Description
Page No.
General Technical Specification & Scope Specification for Civil Works Specification for Electrical Works Specification for Instrumentation Works Specification for Mechanical Components Special Conditions of Contract
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Total Pages
4 25 113 204 236 444
21 88 91 32 208 12
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GENERAL TECHNICAL SPECIFICATION & SCOPE OF WORK
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1.0
SCOPE
1.1
The intent of this requisition is to outline the requirements of the purchaser for the design, engineering, procurement, fabrication, assembly, supply, inland transportation, receipt at site, storage, construction, installation, painting, hook-up, testing, trial run and commissioning of the complete additional liquid coal tar pitch storage tank with transfer facilities for Green Anode Plant, in accordance with the specification and drawings enclosed with this requisition. This is primarily aimed at replication of existing storage and transfer facilities already working in Green Anode Manufacturing Plant-2.
1.2
The plant shall be a complete operating unit including all required auxiliary equipment for efficient and satisfactory operation as a whole. Contractor shall be responsible for furnishing all mechanical, electrical, instrumentation, other interconnecting, safety items, and fire protection equipment as required to make the system complete. Contractor shall be responsible for furnishing all specified equipment and documentation.
1.3
All equipment and materials supplied and installed under these specifications and drawings shall be installed in accordance with sound engineering principles and good fabrication and construction & globally acceptable industrial practices. No omission from these specifications shall relieve the contractor of his responsibility. All materials supplied under this requisition shall be adequate for the proposed service. Proper considerations shall be given to their function with regard to corrosion, chemical and other processes and fire hazards and erosion due to the medium being handled.
2.0
GENERAL INFORMATION
2.1
Introduction National Aluminium Company Limited, (NALCO), a premiere Public Sector Enterprise (Govt. of India Undertaking) is one of the Asia’s biggest integrated Alumina-Aluminum producer with state of art technology. The company currently producing more than 3,50,000 MT of primary aluminium in the form of Ingots, Alloy Ingots, Billet, Rolled products, Wire Rods and Sow. The company has multi location facilities like Mining & Refinery at Damanjodi, Koraput district of Orissa, and power plant & Smelting units at Angul district of Orissa. The company after finishing its first phase of expansion currently undertaking second phase of expansion in all the units. Nalco also is exploring to add green field to expand its capacities further. Nalco with a turn over of more than Rs. 5000 Crores has net profit of Rs. 2300 Crores in last financial year.
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The current requirement is in Smelter plant, located at Angul district of Orissa. The proposed system would meet the requirement of liquid coal tar storage, handling and transfer for our green anode manufacturing plant. Nalco being all its processes are certified with ISO-9001 quality management system, ISO-14000 Environ management system and OSHAS-18001 system, looking for capable quality conscious vendors to provide world class service in the field of turnkey project handling including engineering, designing, manufacturing, installation and commissioning. The project management cell is fully equipped with experience professional to guide, monitor and manage project and can match best in the industries. Location The plant and equipment to be supplied under this Lump Sum Turnkey Requisition will be installed in National Aluminium Company Limited's Aluminium Plant located at a site approximately 5 kms from the nearest town of Angul in the Orissa State in India. The site is connected by a 1 Kilometer long linking road to the existing highway NH 42 linking NH 5 (Calcutta, Madras) and NH6 (Calcutta-Bombay) and connected with Talcher.(Railway Station). Nearest Railway Station : East Coast Railway, Broad gauge (1.676m) 1. For passenger traffic: Angul Railway Station , 7 km away with the opening of Talchar-Sambalpur rail line from plant site. 2. Goods in rakes and Wagons: Bhudhapank - NALCO siding (SCPM) 11 km from Smelter. 3. Goods in small consignment: Talcher, about 25 Km from smelter
2.2
Nearest Port
:
Paradeep Port - 190 km from smelter.
Nearest Airport
:
Bhubaneswar - 140 Km from smelter.
Transportation of Equipment and Material Limit dimensions for transportation of consignments after loading: By rail (board gauge) Overall height from rail level at top centre
: 4.1148 M
Width at the maximum height
0.6096M
Overall height from rail level at sides
:
3.5052 M
Overall width
:
3.048 M
Normal truck length
:
6.0 M
Normal truck width
:
2m
By Road
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Normal truck height from road level
:
3.22 M
Maximum Gross Weight on Plant Roads
:
10 Tonnes/Axle
Site Conditions and Climate Air Temperature
Dry bulb °C
Wet Bulb °C
Relative humidity %
Maximum Minimum Design
50 6 50 max./6 min.
25.7 14.8 25.0
83 at 26°C 33 51
Rain Fall Annual
:
Maximum recorded in one hour Maximum recorded in a day Rainy Season
: : :
Maximum : 2148.7 mm Minimum : 756.0 mm Average : 1243.7 mm 100 mm 257 mm Mid June to mid September
Maximum
:
1001.4 MB (Avg.monthly)
Minimum
:
981.6 MB (Avg.monthly)
Average
:
Barometric Pressure
0830 Hrs. (Morning) - 993.5 MB 1730 Hrs. (Evening) - 989.3 MB
Design
:
981.0 MB
Wind direction
:
West and North-West
Wind velocity
:
180KmphMax.
Max.Wind pressure
:
At 10 m
: 193 da N/ m2
At 20 m
: 219 da N/m2
At 30 m
: 231 da N/m2
Wind
Atmospheric Conditions ashes,
:
Standard industrial atmosphere with possibility of hails storms (hails upto 600 grams).
2.3
Soil Data
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Refer “ Specification of Civil works 2.4
Seismic Data Refer “ Specification of Civil works”
3.0
DESCRIPTION OF PLANT & AUXILIARIES
The Green Anode Plant is required for producing green anode blocks of fixed dimensions and Petroleum coke, recycled baked anode scrap and recycled green anode scrap in fixed grain sizes and proportion and coal tar pitch in fixed proportion are continuously mixed to produce homogenous paste before moulding it into green anode blocks on vibrocompacting machines and then cooled in cooling tunnel. Liquid coal tar pitch is received through specially built tanker, which is than unloaded to the pitch storage tank by the help of pitch unloading pump. Simultaneously two nos. of tanker can be loaded to the storage tank. The pitch pump and the pitch tank are maintained at a temperature by circulating heat transfer thermic fluid. The liquid coal tar pitch are pumped from the storage tank and fed to the process as and when required.
3.1
3.2
Utility Systems: Following utility connections will be provided at the battery limits. i) ii) iii) iv) v) vi) vii)
4.
For Electrical refer enclosed Electrical specification. Dry compressed air . Cooling Water Clarified & filtered water Fire Water Sprinkler water Drinking water
DESIGN BASIS
4.1 Plant and Equipment 4.1.1
The Liquid pitch handling system shall be designed as, No. of shifts per week No. of 8 (eight) hour shifts per day No. of production weeks per year
21 3 46
4.1.2
Process flow sheet for liquid pitch handling system is available with this document.
4.1.3
Plant shall be laid out and constructed for convenience and safety of operation and maintenance. All equipment shall be oriented to permit servicing in such a way so as to require minimum dismantling.
4.1.4
All equipment shall be of proven design. Prototype or extensive modifications of basic designs are unacceptable.
4.1.5
All equipment and structures shall be designed for installation at location with environmental and seismic conditions as stated elsewhere in this specification.
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4.1.6
All electrical systems shall be in accordance with Electrical specification enclosed.
4.1.7
All instrumentation and controls shall meet the requirements of the instrumentation works specifications enclosed.
4.1.8
The architectural design of buildings in the plant shall be as per the architectural technical requirement enclosed.
4.1.9 Civil works shall be as per civil - structural works specifications enclosed. 4.1.10 All general civil works (approach roads, pavement, earth disposal, storm water drainage, plumbing works, sanitary, fire protection facilities etc.) shall be provided and executed in accordance with enclosed. 4.1.11 All piping, valves and fittings and piping works shall be in accordance with the piping specifications enclosed. 4.1.12 Complete system, equipment and material to meet any emergency power requirements for safe start-up, operation and shut down, if required, shall be provided by the contractor and shall be self-sufficient. 4.1.13 Equipment and piping shall be insulated as per insulation specification enclosed. 4.1.14 All equipment shall be painted as per enclosed specification.
4.1.15 The layout has to be such as to provide adequate space for ease of operation and maintenance. Contractor is required to demonstrate the adequacy of operation and maintenance space and provision through a 3D model during layout drawing review stage after order. 4.1.16 All other equipment and materials (mechanical, piping, electrical, instrumentation, controls, civil, structural, architectural etc.) shall be sourced from contractors acceptable to NALCO. 4.2
Codes and Standards The design, fabrication, supply and testing shall conform to codes and standards listed below and specified elsewhere in this material requisition. Contractor may also base his design on other international standards subject to approval of owner. Only latest editions as on last date of last offer including addenda shall always be referred to:
4.2.1
Safety Design, fabrication & operation of plant shall be based on the following. a) Indian factory Act. b) Indian Explosive Act. c) Indian Electricity Rules. d) Fire Protection Manual of Fire Sectional Committee Insurance Assoc. of India. e) Regulations laid down by Explosive Directorate and Electrical Inspectorate. f) Regulations of Director General of civil Aviation for all stacks
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g) NFPA Code of Practice. h) Regulation for Electrical Equipment of Buildings Insurance Association of India. i) Regulations of both central and state Pollution control Boards for overall pollution control for both surface and air. 4.3
Safety of Plant and Personnel
4.3.1
Noise level shall not exceed 85 db(A) at any place within the green anode plant measured at a distance of 1 m from single piece of equipment. Each machine and motor shall be considered as one equipment. However, for equipment such as ball mill, vibrating screens, paste mixer, paste cooler, exhaust fan, etc. housed inside rooms with acoustic enclosure, the noise level shall not exceed 85 db(A) at 1 m distance from such rooms.
4.3.2
Air Conditioning (If applicable) Inside conditions to be maintained in control room round the clock are as under: DBT : 22 ± 2°C RH : 55 ± 5 %
4.3.3 Pressurisation and Ventilation Pressure inside the electrical switchgear room to be maintained at minimum + 3 mm WG and the temp, inside the switchgear & laboratory rooms shall not be more than 5°C above ambient temperature. For ventilated enclosures/rooms for ball mill, vibrating screens, preheating screw, paste mixer and paste cooler, the temperature inside these enclosures/rooms shall not be more than 5 deg. C above ambient temperature. Vendor shall provide minimum number of air changes as follows: For ventilation of acoustic enclosures, suction and discharge ventilation air shall be taken from outside the building (1 meter minimum).
5.
EXTENT OF SUPPLY AND SERVICES
5.1
Scope of Supply:
5.1.1 The scope of supply under this requisition shall cover all equipment, materials and supplies for the complete Pitch storage tanks, loading & unloading facilities as per enclosed process flow diagrams and specifications specified in the document. All auxiliary and associated equipment such as pumps, drives, MCC with MCC room, PLC, piping & valves shall be inclusive in the scope of work. A building for MCC which shall house MV switchboard, Lighting Panels and all other indoor electrical and instrumentation equipments to be constructed by the vendor. Contractor's scope shall include all equipment, materials and supplies within the battery limits of the proposed work so as to make the system complete in all respects for safe and efficient operation of the plant as a whole as turnkey contract.
5.1.2 Following battery limits shall be applicable. o
Heat Transfer Fluid shall be provided from the existing Circuits as shown in the schematic.
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o
For all utilities like clarified and filtered water, cooling water, drinking water, fire, water, sprinkler water : From a single point connection 50 meters from Green anode plant boundary limit.
o
Dry compressed air shall be provided at battery limit at a single point 5 meters away from plant boundary.
5.1.3
All electrical systems shall be in accordance with Electrical specification enclosed.
5.1.4
All instrumentation and controls shall meet the requirements of the instrumentation works specifications enclosed.
5.1.5
Civil works shall be as per civil - structural works specifications enclosed. Cement & Reinforcement Steel Shall be issued from Nalco as Free Issue Material. After placement of Work order vendor is required to indicate approximate quantity of cement & steel in advance. Reconciliation of free issue material has to be done as per actual measurements.
5.1.6
All general civil works (approach roads, pavement, earth disposal, storm water drainage, plumbing works, sanitary, fire protection facilities etc.) shall be provided and executed in accordance with enclosed.
5.1.7
All piping, valves and fittings and piping works shall be in accordance with the piping specifications enclosed.
5.1.8 All materials and supplies for the equipment, ducts and piping supports, building structures, electrical equipment shall be a part of the contractor's scope of supply. 5.1.9 All equipment and materials up to the battery limit for the total plant's fire-detection and fire fighting systems to meet the applicable codes and standards shall be included in the contractor's scope of supply. TAG Norms /Regulations shall be followed and necessary statutory approval for GAP shall be included in Contractor's scope.
5.1.10 In addition to plant, equipment and auxiliaries, the contractor shall include, in his scope of supply, the following items: a)
Special tools and tackles as per commercial part of contract.
b)
Initial-fill of lubricants oils, grease for all equipment.
c)
Start up spares & Spares for two years normal operation
5.1.10 Any additional item or feature required during detail engineering for the completeness and trouble-free performance of the plant shall be included in the contractor's scope without any cost and time implications, as long as the system performance requirements within the battery limits of the plant are kept unchanged. 5.1.11 All piping, cables, electrical, etc between units and in between equipment within battery limit shall be in the scope of contractor. 5.1.12 All interconnecting piping and cables above ground between various units / areas shall have minimum 7.5 meters clearance below them for movement of vehicles.
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Scope of Services: Contractor shall include the following services & works including supply of materials, necessary equipment and facilities for the Liquid Coal Tar Pitch Handling & Storage system on a turnkey basis: a) b) c) d) e) f) g) h) i) j) k) l)
Design and Engineering Procurement of equipment and material Fabrication and assembly at works Transportation including inland transportation Receipt at site and storage Site fabrication Site construction and civil works Installation and hook-up. Equipment shop testing and final testing of the system at site. Painting, including supply of paints. Mechanical completion and commissioning. Performance Testing of the complete plant at site.
TECHNICAL SPECIFICATION 6.0
Technical Requirement
6.1.1 Coal Tar Pitch Softening Point (Mettler)
:
Density
105°C to ll5°C
:1.30 grams/cc (M inimum)
Fixed carbon (SERS)
:
Resin Alpha (Quinoline Insoluble)-Ql :
52% Minimum 5 to 12%
Resin Beta (Tl-Ql)
:
20% minimum
Viscosity at 140° C
:
2 x 104 CPS maximum
Viscosity at 160°C
:
3 x 10 3 CPS maximum
Ash content
:
0.5 maximum(weight difference
Sulphur content
:
0.5% maximum
Water content
:0.5% maximum ignition)
after ignition)
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Utilities a) Cooling water & clarified & Filtered water Cooling Water
Clarified and Filtered Water
pH
7 to 8.5
7.0 to 7.5
Total Hardness as CaCo3
60 to 300 mg/l
300 mg/l
Temp. Inlet
30°C to 35°
Ambient
Temp. Outlet
40°C to 45°C
Supply pressure
3 bar (g) [minimum]
Return pressure
2 bar (g) [minimum]
b)
Power
:
Refer Electrical specifications
c)
Compressed air
:
6.0 bar (g) minimum Dew point : -30 °C at atmospheric Pressure
1.5 bar (g)
d) Drinking water : 0.5 bar (g) minimum (for drinking and safety shower) at battery limit. The booster pump to achieve the required pressure including surge tank for half an hour consumption shall be provided by contractor.
6.2 6.2.1
e)
Fire water
:
7 Kg / cm2g
f)
Sprinkler water
:
7 Kg / cm2g
g)
Heat transfer fluid Specification equivalent
:
Servotherm-S -Medium of IOC or
Mechanical Equipment Liquid pitch handling, storage and feeding Liquid pitch handling, storage and feeding shall be as per enclosed & along with various documents referred therein. Constructional Features: (Pl. see drawing Nos: GAP1/PRJ/SCH/A1/8101, GAP1/PRJ/LAY/A1/8102, GAP2/PRJ/TRC/A1/7592 sheet 1 to 3, GAP2/PRJ/TRC/A1/7593, GAP1/PRJ/TRC/A1/7598, GAP2/PRJ/TRC/A1/7597, GAP1/PRJ/TRC/A1/7594)
Features: 1) Pump for pitch service shall be double walled type and shall be Positive Displacement pump. Pump shall supported by antifriction bearings and no cooling required for the pump. 2)
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Capacity of pitch pumps shall be 30 m3/hr. DOCUMENT TITLE
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3)
Storage tanks shall be as per enclosed specification along with additional features listed below.
4)
Basket filter shall be as per standard specification specified in the document. Filter element must be of #2mm.
5)
Insulation cladding requirement for pitch shall be Aluminium. For insulation, moulded or pre-fabricated ceramic insulation shall be used. Loose wool, fibers, pads shall not be permitted.
6)
There shall be provision to transfer liquid coal tar pitch from proposed storage tank to existing pitch tanks in the system. (Pitch tank – 1,2,3 & 4)
7)
The entire unloading & transferring operation are to be fully automatic through PLC/SLC System.
8)
Pitch Unloading: Normally liquid pitch is received by tanker at a temperature between 190-210oC. The proposed system shall have four independent unloading stations as shown in the layout with transfer pumps. Pitch is transferred 30 M3/ Hour capacity pitch pumps through flexible metallic flanged hoses. Two- three nos. of tankers are to be used simultaneously for unloading. The areas on which the tanker stands during unloading are covered by concrete slabs. Pitch is stored in thermally insulated storage tank (300 M3, proposed Tank # 5 & 6 ) equipped with circulation of heat transfer fluid for maintaining liquid pitch temperature inside the tank. The liquid pitch is continuously stirred with the help of stirring pump (30 M3/ Hour) to maintain uniformity & mixing of hot and liquid pitch inside the tank. The feed of stirring pump has to reach bottom of the tank to facilitate during cold start. The pitch intake shall be located in the lower part of the storage tank and the pump shall discharge in to upper part of tank. Each storage tank is located within a retention enclosure. The volume of this retention enclosure must exceed that of storage tank. Each storage tank built on concrete plinth in such a way that the bottom of the tank is higher than the level of the retention basin. The retention basin is equipped with a rainwater drainage system. This system incorporates a trap for retaining pitch if leakage occurs. Storage Tank: The storage tank is fabricated steel construction with a flat bottom and slightly conical roof. Each storage tank shall have,
-
A high level manhole
-
A low level manhole
-
An access stair and decking on the top of the storage tank
-
A float gauge and graduated scale clearly visible from the ground
-
A high level detector with automatic filling shut off device
-
A vent incorporating vapor trap
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-
A drain valve
-
A outlet for collection of sample from the tank at feeding point
-
A temperature probe.
-
Thermal insulation comprising of mineral wool layer protected by a blanket and Aluminium cladding
-
An ultrasonic level detector
-
The installation shall be designed in such a way that, it is possible to drain all the equipment and piping in the event of extended shutdown.
-
Storage tank structural design shall take in to account local regulation currently in force.
The temperature of the liquid pitch inside the storage tank is maintained by automatic regulation of HTF fluid circulation. The circulation to the tank is through a bunch of pipes, which are arranged mainly around the lower part of the tank. The temperature pf the upper part shall be maintained by a loop, which shall extend above the top level of liquid pitch. The HTF supply to the jacketed piping shall be maintained from existing circulation point from U – 142 A/B pumps. The pump shall be of 20 M3/ Hour capacity and 55 meter head. The HTF circulation to the tank shall be maintained from U- 125 A/B (80 M3/ Hour, 25 meter Head). The circulation of the pump to pipes and the tank shall be fully automatic and regulated by PID control. The heat transfer to the tank is to be achieved by circulating heat transfer fluid through shell and tube type heat exchanger. Provision of additional heating from bottom of the tank shall be provided by electric coil if required by the client at the time of construction. All the pitch pipe work, valves, pumps shall be double walled and heated by circulation of heat transfer fluid. All such equipments shall be thermally insulated and thermal insulation shall be protected by Aluminium cladding. Valves selected shall be coated with suitable lining to provide 100 % sealing at the required temperature. Because the pitch is abrasive, the speed of the rotation of the pumps shall be as low as possible. Valves are to fitted with limit switches for preventing startup of the pumps if the valves are not opened. The rotation speed of the pump shall be lower than 200 RPM. The installation supplies paste plant with liquid pitch at a given temperature. It should be possible to adjust the temperature between 160 and 200 degree Celsius. The liquid pitch is distributed from the storage tanks to the paste plant by two pumping assembly (One is standby) with one booster and one regulation loop. The heat required to maintain liquid pitch temperature in the installation is supplied by means of heat transfer medium. The pumping assembly comprises of two pumping units (30 M3/ Hour) each one having one positive displacement rotary pump and one filter positioned in the pump suction part. All
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the pumping station with allied accessories shall be under steel shed and GI roofing to protect adequately from rain and other weather conditions. 6.2.2
Heat transfer fluid system (HTF)
i)
Heat transfer fluid system shall be as per enclosed specification along with various documents referred therein.
ii)
HTF pumps shall be horizontal centrifugal pumps. air cooled and supported by antifriction bearing. Normal brand preference shall be ALLWILLER or KSB. Suitable throttling shall be provided for controlling flow and pressure to the storage tank HTF circuit.
iii)
Shell and tube heat exchanger for HTF - pitch service shall be as per specifications available in the documents.
iv)
All pumps for HTF system shall be provided with installed standby.
v)
HTM pumps material of construction shall be as per table S6 in accordance with API Standard 610 and the HTM pumps shall be air-cooled.
vi)
All equipment and piping are thermally insulated by ceramic prefabricated/ moulded pad with an outer protective layer of aluminum cladding. The insulating components installed must be able to withstand the assembling and dismantling necessary for subsequent operation.
vii)
Insulation cladding requirement for HTF shall be Aluminium.
viii)
HTM pipes shall be carbon steel seamless pipe. Flanges, bends and elbows shall be as per ANSI suitable to application. The ducts/ piping shall be designed for minimum 600oC.
ix)
Valves will be of Bellow Seal Type and forged up to 3” size and fabricated >3” Process: Heat Transfer fluid will be provide by the owner at a specified point from green Anode Plant-1. However piping, looping, valves, pumps, system, control etc. are to be provided by the vendor for completing circulation system to the proposed pitch tank and loading/ unloading system. Vendor has to provide two nos. of HTF pumps for maintaining temperature and pressure of the HTF for storage tank and two nos. of pumps for entire piping. . One pump will be normally operated and one will be standby. The operation of the pumps shall be made fully automatic through thermometric sensors situated at the inlet and outlet of the circulating fluid to the proposed system. Heat Transfer Fluid from GAP-1 will be supplied to the proposed system at the time the Pitch Melters are not operating. Hence vendor has to provide suitable isolation
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and control mechanism to shutoff and opening of the valves to suit operational needs. The system shall be operated through electro-mechanical valves. 6.3
Electrical Works All electrical works covered and to be executed under this requisition on turnkey basis are specified in 'Scope of Work and Technical Specification for Electrical system. This shall also include the construction of MCC room specified elsewhere in the documents.
6.4
Instrumentation and Control Works All instrumentation and control works related to the Green Anode Plant to be provided by the contractor are specified in enclosed. Instrumentation job specification.
6.5
Civil - Structural Works All civil and structural works pertaining to the Green Anode plant shall be furnished and Executed in accordance with enclosed specification/ Drawings enclosed.
6.6
Storage tanks Vessels and storage tanks for the proposed work shall be provided and executed in accordance with the enclosed specification for vessels and storage tanks.
6.9
Piping works All piping works shall be provided and executed in accordance with standard piping specification for package units as per ASTM/ANSI.
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7.0 DRAWING AND DATA REQUIREMENT The following data and information shall be furnished by the contractor : With Bid
After Job Award
1
2
3
4
For Information
Final in Book Form
Description
For Review
Sl No.
5
6
1.
System flow diagrams with material balance and equipment list.
X
X
X
2.
Basic calculations for system design, equipment selection and sizing, characteristic curves for pumps, blowers etc
X
X
X
3
Makes of all equipment
X
X
X
4
Technical literatures.
X
5
Control schematics (basic)
X
X
X
6
Process and instrumentation diagram.
X
X
7
Bill of material and schedule of quantity.
8
Overall general arrangement drawing.
X
X
X
9
Completed data sheets adequately covering information for reviewing such as selection, and sizing of equipment and package, drive arrangements and rating selection etc.
X
X
X
10.
Material of construction of all parts.
X
X
X
11.
Un-priced copy of Purchase specification (shop work-order, in case package/equipment is manufactured by contractor) for all equipment and packages covering their sizing and selection. (Before order placement).
12.
Utility requirements.
13.
Foundation design basis.
SMELTER DIVISION
X
X
X
X
X
X
X
X
X
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With Bid
After Job Award
1
2
3
4
For Information
Final in Book Form
Description
For Review
Sl No.
5
6
1.
System flow diagrams with material balance and equipment list.
X
X
X
2.
Basic calculations for system design, equipment selection and sizing, characteristic curves for pumps, blowers etc
X
X
X
3
Makes of all equipment
X
X
X
4
Technical literatures.
X
5
Control schematics (basic)
X
X
X
6
Process and instrumentation diagram.
X
X
7
Bill of material and schedule of quantity.
8
Overall general arrangement drawing.
X
X
X
9
Completed data sheets adequately covering information for reviewing such as selection, and sizing of equipment and package, drive arrangements and rating selection etc.
X
X
X
10.
Material of construction of all parts.
X
X
X
11.
Unpriced copy of Purchase specification (shop work-order, in case package/equipment is manufactured by contractor) for all equipment and packages covering their sizing and selection. (Before order placement).
12.
Utility requirements.
13.
Foundation design basis.
SMELTER DIVISION
X
X
X
X
X
X
X
X
X
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7.2
7.3
PROJECT TITLE
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ADDITIONAL LIQUID PITCH HANDLING SYSTEM
20 of 455
Document distribution schedule 1
Documents and drawings under column no. 3 shall be submitted with each copy of the bid.
2
Documents listed under column 4 are to be submitted in 8 copies (6 copies to consultant, 2 copies to owner).
3
Documents listed under column 5 are to be submitted in 8 copies (6 copies to consultant, 2 copies to owner).
4
Documents listed in column 6 are to be submitted as hard bound indexed book containing the following details in Twelve (12) copies, 2 transparencies, 1 soft copy and to be submitted within 4 weeks of release note/ despatch of materials/ equipment from contractor's works. All transparencies to be supplied in rolls (in two sets). One soft copy to be supplied in CDs.
Details to be included in Final Documents Books 1
Copy of P.O. and all amendments.
2
Copy of Purchase Requisition and all amendments.
3
Manufacturing Data Book containing all test certificates of components, raw materials, stage manufacturing tests and inspections, final tests & inspection documents including welders' qualification & welding procedure qualification, repairs & reworking carried out in shops.
4
All raw material test certificates must be correlated to the P.O. Item No. & component to which they relate by clear noting on the certificates.
5
Spares details including assembly drawings, part numbers, delivery, prices and ordering information.
6
All design calculations carried out by the contractor where agreed specifically.
7
Final Drawing Index and all as-built drawings reduced to A3/A4 size and wherever reduction is not possible, full size copies duly folded and placed in plastic pockets.
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ADDITIONAL LIQUID PITCH HANDLING SYSTEM
21 of 455
8
Catalogues/leaflets of sub-vendors/suppliers of various bought out components highlighting the components actually supplied correlated to P.O. Item Numbers.
9
Operating and maintenance instructions including lubrication schedules with requirements of 1st fills, flushing fluids, inhibitors, chemicals required for precommissioning together with pre-commissioning & commissioning procedures wherever applicable with details of suppliers for procurement by NALCO for subsequent needs.
10
Release Note and Packing List.
11
Any other documents asked for in the Purchase Requisition.
7.4
Special instructions for submission of Drgs./Documents to NALCO : 1. Fold all prints to 216 MM x 279 MM size & roll transparencies.
2. Contractor to forward the drawings and documentation to NALCO clearly specifying purchasers Job no. & Reqn. No.t 3. The drawing/Document no. with Rev.No. is essential. The number may be upto a maximum of 28 characters in length. 4. Each Drawing/Document submitted must be checked and signed/stamped by contractor before it is submitted to NALCO. 5. Revision number must change during subsequent submission of contractor document. 6. Multi-sheet documents other than drawings mast be submitted in their entirety in the event of a re-submission even if only a few sheets are revised. 7. Final submission in bound volumes shall necessarily have a cover page giving project title, Item name, P.O.No. particulars of owner & contractor and an index giving list of drawings & documents included (with revision no.). 8. All contractor drawings to be provided with a blank space measuring 75 mm W x 38 mm H for marking of review codes etc. by NALCO. 9. The review of the contractor drawings shall be done by NALCO, as applicable, under the following review codes : Review Code “1” No comments. Review Code “2” Proceed with manufacture/fabrication as per Commented drawings. Revised drawings required. Review Code “3” Document does not confirm to basic requirements.
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10. Review of contractor drawings by NALCO would be only to check compatibility with basic designs & concepts & would in no way absolve the contractor/contractor of his responsibility to meet applicable codes, specifications & statutory rules/regulations. 8.0
INSPECTION & TESTING
8.1
Each individual equipment shall be shop tested as per the applicable codes and standards for performance and pressure. Contractor shall perform the required tests necessary to fulfill the acceptable noise and vibration limits. Dynamic balancing test for pumps, fans, blowers etc. shall be performed, as required. Manufacturer's Quality Assurance Plan (QAP) shall take care of requirements as per enclosed standard specification.
8.2
The contractor shall give performance test at works for pumps. In addition to the above, performance testing of complete system shall also be done at site by the contractor.
8.3
A functional test shall be performed for the instrument and control system for individual equipment and also the plant as a whole. Contractor shall provide all the necessary interconnections for the purpose of shop tests.
8.4
Periodic inspection of the fabrication assembly and packaging of the system may, at the owner's option, be performed to assure conformance with the purchase order by the owner or its authorized representatives, and as per inspection procedure mentioned in General purchase conditions.
8.5
Any or all the tests may, at the owner's option, be witnessed by the owner or its representative. However, such inspections shall be regarded as check-up and in no way absolve the contractor of his responsibility.
8.6
After installation and commissioning at site, the units shall be tested for overall performance as per procedures mutually agreed upon. All instruments and gadgets for testing at site shall be arranged by the contractor at his own cost.
9.0 9.1
PERFORMANCE GUARANTEE All equipment and components shall be guaranteed by the contractor against any defective material, design and workmanship for the period of 18 months from the date of supply or 12 months from the date of installation whichever is later specified in commercial part of the bid document.
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9.2
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ADDITIONAL LIQUID PITCH HANDLING SYSTEM
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The complete system and individual equipment must be designed and built to ensure, under normal conditions of operation, the rated capacity as per specifications are achieved.
9.3 The contractor shall have final and total responsibility for the design and mechanical performance of the complete plant supplied under the contract. The contractor shall warrant the plant furnished by him and the performance of said plant in accordance with this specification and Annexure 1, 'Performance Guarantees and Performance Testing', forming part of this Purchase Requisition. 10.0
SPARE PARTS
10.1
Proper coding and referencing of spare parts shall be done so that later identification with appropriate equipment will be facilitated.
10.2
Contractor shall also guarantee that commissioning spares, if required over and above the commissioning spares included in the order shall be made available without any cost and time implication to the owner. If, for any reason during commissioning, contractor needs to utilize spares from quantity of spares as per list, he will replace the same free of cost to NALCO, duly delivered at site including all freights, insurance, taxes and duties.
11.0
SPECIAL TOOLS AND TACKLES The contractor shall provide a set of new and unused special tools and tackles required for operation and maintenance of the furnished plant as per commercial part of the contract.
12.0
PAINTING AND SHIPMENT
12.1
Equipment and materials supplied shall be painted after tests at shop and after installation & testing at site in accordance with the Specification for Shop and Field Painting. This specification shall supersede all painting specification covered under various standard equipment specification enclosed with this requisition except any special requirement mentioned elsewhere. Sand or other potentially silicon containing materials shall not be used as abrasives for blast cleaning because of safety regulations.
12.2
The units shall be disassembled into major components suitable for shipment and shall be properly packed to provide adequate protection during shipment. All assemblies shall be properly match marked for site erection.
12.3
All machined and bearing surfaces shall be protected against rust with a thick coat of grease. Each equipment shall have an identification plate giving salient equipment data, make, year of manufacture, equipment number etc.
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13.0 VENDOR LIST FOR ITEMS:
Sl. No Item Vendors 01. Pitch Pumps VIKING/ JOHNSON 02. HTF Pumps ALLWEILLER/ KSB 03. THERMIC VALVES( BELLOWS SEAL KLEIN/ AZ ARMATUREN GLOBE VALVES) 04. JACKETED PLUG VALVES TUFLIN/XOMOX/ AZ ARMATUREN 05. Electrodes/ MIG wire Eutectic/ Diffusion/ Modi 06. Field Instruments Danfoss 07. Insulation(Pre-formed/Pad) Lloyds/ Murugappa/Rockwool 08. Steel Plates SAIL/TISCO/JINDAL/IISCO 09. PIPES Prakash/ Surya/ Jindal 10. Fasteners TVS/ Unbrako/ Precision 11. UTILITY Valves AUDCO/KSB/VIRGO 12. Power Cables LAPP/Finolex/PolyCab 13. Motor SEW/DEMAG/Simens/Kirloskar/ ABB 14. Panel Rittal 15. MCC Switchgear L&T/ Schneider 16. Sequence Controller/ SLC/ I/O Allen Bradely/ SIEMENS Cards 17. Paints Berger/ Asian/ Dulux 18. Load Break Switch Socomec/Ferraz CEFM
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STANDARD SPECIFICATIONS FOR CIVIL WORK
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SPECIFIC WIND AND SEISMIC LOAD DATA
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1.0
WIND LOAD
1.1
Wind load shall be calculated for Aluminium Smelter Expansion site as per IS 875 (Part 3)-1987 and specific data provided here below.
1.2
Basic wind velocity Vb
1.3
Kl
:
=
50 M/Sec. as per Fig. 1 of IS 875 Part-3.
Probability Factor As per Table 1, Kl = 1.08 for Vb = 50M/Sec.
K2
:
Terrain, Height and Structure Size Factor. i)
Terrain Category 2
ii)
Structure Size Factor
Class A : Structures having maximum horizontal or vertical dimensions less than 20M.
1.4
K3
:
Topography Factor
K3
:
1.0 for a Flat Industrial Area, shall be taken into account.
i)
Design Wind Velocity is given by : Vz
ii)
=
K1.K2.K3. Vb
Design Wind Pressure is given by : Pz
0.6(VZ)2N/M2
=
4J
0.0612 (Vzp Kg./M2) 1.5
Where Vz is in M/Sec. Based on above, Design Wind velocity and Design Wind Pressure are indicated here below which shall be adopted for design of equipments of Class A (structures having max. horizontal or vertical dimension less than 20M). Height (Meters) Upto 10 15 20 25 30 35
SMELTER DIVISION
K2 Factor
Vz (M/SEC.)
1.00 1.05 1.07 1.095 1.12 1.132
54.0 56.7 57.78 59.13 60.48 61.13
Pz (Kg./M2). 179 197 205 214 224 229
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40 50
1.145 1.17
61.83 63.18
234 245
2.0
SEISMIC LOAD
2.1
Seismic load shall be calculated for Aluminium Smelter Expansion Project site as per IS: 1893 - 1984 based on specific data provided here below:
2.2
a)
Seismic Zone
b)
Importance Factor
c)
Damping
:
2%
d)
β
:
1.0 (min.)To be based on soil foundation system
e)
Method for calculation for ah
f)
:
III :
Response Spectrum Method :
Cth
2.0
Horizontal Seismic Coefficient.
2.3 For stack like structures (vessels, column, silos and tanks), time period, shear force, bending moment shall be calculated as per clause 5.3 of Code IS: 1893-1984. 2.4
EARTHQUAKE AND CONCURRENTLY
3.0
Deflection of Column
WIND
SHALL
BE
CONSIDERED
NOT
ACTING
Maximum allowable deflection at top of column shall be equal to height of the column divided by 200. 3.1
If the deflection of column exceeds the above allowable limit, the thickness of skirt shall be increased as first trial upto a maximum value equal to the column thickness and this exercise shall be stopped if the deflection falls within allowable limit.
3.2
If the above step is inadequate, skirt shall be gradually flared to reduce the deflection. Flaring of skirt shall be stopped if the deflection falls within limits or half angle of cone reaches maximum limit of 9°.
3.3
If the above two steps prove inadequate in limiting the deflection within allowable limits, the thickness of shell courses shall be increased one by one starting from bottom course above skirt and proceeding upwards till the deflection falls within allowable limits.
4.0
Stress Limits The stresses due to pressure, weight, wind/seismic loads shall be combined using maximum principal stress theory for ASME Section VIII Div.I. Thick nesses are accordingly chosen to keep the stresses within limits as per Table-2.
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5.0
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Skirt Support Base Base supporting including base plate, anchor chairs, compression ring, foundation bolting etc. shall be designed based on over-turning moment (greater of seismic or wind). A minimum number of 8 foundation bolts shall be provided. Nos. of foundation bolts shall be in multiple of four.
6.0
Minimum Hydro test Pressure Minimum Hydro test Pressure shall be equal to 1.5 x design pressure x temperature correction factor, as specified in ASME Code Section VIII Div.I (Clause UG-99). The term test pressure shall apply to the pressure measured at the highest point of vessel in its operating position and shall be applied to the highest point in its test position.
7.0
Dynamic Analysis of Column Dynamic analysis of each column shall be carried out for stability under transverse wind induced vibrations as per standard design practice and calculations for each column shall be submitted to NALCO for approval. The recommended magnification factor for unlined towers/column shall be taken as 70 and allowable dynamic amplitude shall be limited to tower diameter divided by five. TABLE-1 DETAILS AND WEIGHT OF COLUMN ATTACHMENT
1.
Shape factor for shell wind force calculation)
2.
Weight of trays (with liquid) to be considered.
120 Kg./m2.
3.
Weight of plain Ladder
:
15 Kg./m
4.
Weight of caged ladder
:
37 Kg./m
5.
Equivalent projection to be considered for load on caged ladder
:
300 mm wind
6.
Distance of platform below each manhole
:
Approx. 1000 mm
7.
Maximum distance between consecutive
:
5000 mm platforms
8.
Projection of Platform
:
900 mm upto 1 meter dia. column and 1200 mm for column dia. > 1 meter, from column insulation surface.
SMELTER DIVISION
:
0.7 (for
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9.
Equivalent height of platform (for wind load computation)
10.
Weight of platforms
11.
Platform shall be considered all around
1000 mm
170 Kg./m2.
:
TABLE-2 (ALLOWABLE STRESSES FOR COMBINED LOADING)
CONDITIONS
VESSEL CONDITION/TEMP. TYPE OF STRESSES ERECTION
OPERATING
TEST
NEW
CORRODED
CORRODED
AMBIENT
DESIGN
AMBIENT
KxSxE
KxSxE
0.90xYPxE
KxB
KxB
B
NEW OR CORRODED TEMPERATURE LONGITUDINAL TENSILE STRESS LONGITUDINAL COMPRESSIVE STRESS
Where S
=
Basic allowable Tensile Stress as per Clause UG 23(a) of ASME Code Sec. VIII Div. 1.
B
=
'B' value calculated as per Clause UG-23(b).
E
=
Weld joint efficiency of circumferential weld, depending on extent of
radiography. K
=
Factor for increasing basic allowable value when wind or seismic load is present.
YP
=
Yield strength of shell material
Note : Allowable stresses in skirt to shell joint shall be as per following : a)
0.49S, if joint is shear type.
b)
0.70S, if joint is compression type.
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SCOPE OF WORK FOR CIVIL - STRUCTURAL
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1.1.
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SCOPE OF WORK The scope of Civil-Structural works under this contract shall include complete design, detailing, supply and construction of all relevant civil and structural works for two additional Storage Tanks for Liquid Pitch Handling at Green Anode Plant for NALCO Smelter Plant at Angul as per details/specifications enclosed with the bid document. Major civil-structural works involved shall include but not limited to the following: Design and construction/installation of foundations and super structure for MCC & Storage Tank for Pitch, supporting structures for Pitch Storage Tank & associated equipments, support columns (steel) for complete system, pipe/duct supports, stairs, ladders, platforms etc. Bidder to note during design that the new structure is being provided near the existing Green Anode Plant structure. Bidder to check with the interface of nearby structure and foundation to be designed after clearing the nearby foundations. The works shall involve activities as listed but not limited to: -
-
-
1.2.
Setting up of WORKSITE establishment and CONTRACTOR’S facilities. Preparation of fabrication drawings for all structural steel works and bar bending schedules for all RCC works. Structures for Hoists/ Monorails/ Overhead traveling cranes of required capacity for operation/ maintenance of equipment/ fans/ pumps/ walkways/ stairs. Painting of structural steel members shall be as per NALCO Specification enclosed elsewhere with the bid document including supply of paints. All other civil structural works forming part of scope of works of Packaged equipment, Static equipment, Piping disciplines etc. and as laid out elsewhere in this bid package and/ or required/ directed by Owner/ Owner’s representative for the satisfactory and successful completion of the project. Documentation of “AS BUILT” details for all works as specified elsewhere in this bid package.
SCOPE OF SUPPLY All materials (consumables/non-consumables) required to complete the job shall be supplied by the Contractor.
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JOB SPECIFICATIONS FOR CIVIL - STRUCTURAL
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CONTENTS -
GENERAL
-
REFERENCED STANDARDS AND PUBLICATIONS
-
DESIGN CRITERIA
-
DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS
-
MATERIAL REQUIREMENTS
-
CONSTRUCTION REQUIREMENTS
-
SPECIFIC REQUIREMENTS
-
LIST OF ATTACHMENTS
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1.0
GENERAL
1.1
The design considerations given hereunder establish the minimum basic requirements of reinforced cement concrete (RCC) structures, structural steel works and masonry structures. All structures shall be designed for satisfactory performance and functions for which the same are to be constructed. -
All codes referred in this document pertain to BIS (Bureau of Indian Standards) publications and bearing the prefix IS.
-
Whenever any reference to BIS code is made, the same shall be taken as the latest revision (with all amendments issued there to) on the notified date of submission of tender.
-
Apart from the BIS codes mentioned in particular in the various clauses of this document, all other relevant codes related to the specific job under consideration and/or referred to in the abovementioned codes, shall be followed wherever applicable. Reference to some of the codes in the various clauses of this document does not limit or restrict the scope of applicability of other relevant codes.
-
In case of any variation/contradiction between the provisions of BIS codes and the requirements given hereunder, the provisions given in this document shall have precedence over all others. In absence of relevant BIS codes, reference to corresponding British/American codes may be made (in that order of preference).
All designs, detailing and construction shall strictly conform to the enclosed standards, specifications and the subsection ‘Specific Requirements’ included in this document. Only if relevant information is not available in this document, reference to relevant BIS code shall be made. 1.2
The Contractor shall do the structural designing of all structures and prepare complete set of civil and structural drawings needed for correct and accurate construction. The design shall be strictly in accordance with ‘Design Criteria’ given herein.
1.3
Detailed list of drawings/documents [including design calculations, design drawings, bar bending schedules (for RCC works) and fabrication drawings (for structural steel works)] and structure-wise quantity statements (showing anticipated, released and balance quantities of concrete, structural steel and piles) shall be prepared by the Contractor and submitted monthly for review by Owner/Owner’s representative. This list
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shall also indicate the document/ drawing category (approval, review or information as applicable) together with the scheduled and actual dates of submission of the documents. 1.4
Before proceeding with design and drawing preparation the Contractor shall submit detailed general philosophy of design of various parts of (all) the structures and equipment foundations along with explanatory sketches for review by Owner/Owner’s representative. Only after the review and incorporation of comments on the general philosophy, as offered during the review, the Contractor shall submit any design document and/or drawing for review or information or issue the same for construction. Design and detailing of the structures and foundations shall fulfill all functional requirements for which the same is intended and it shall be ensured that adequate accesses, clearances, clearing of interferences, provision of cutouts, etc. have been provided to make the structure/foundation fully operational.
1.5
The design and AFC drawings shall strictly adhere to the reviewed design basis and architectural/structural general arrangement and shall incorporate all the comments/ suggestions given by Owner/Owner’s representative without any extra cost to the Owner and any implication of time-schedule for completion of works.
1.6
Wherever review is carried out the same shall be restricted to following: a) b) c)
Conformance of general arrangement of the structure to already reviewed design philosophy and design basis. Overall framing of the building/conceptual foundation system. Detailed design and drawings including input/ output of computer analysis and design vis-à-vis actual drawing.
Irrespective of the identified structures requiring review, the Contractor is required to submit complete sets of design and drawings of all structures, simultaneously with their respective foundations. 1.7
1.8
(i)
Structural design/drawings for any structure/foundation shall be submitted for review only if referenced input (e.g. architectural drawing, piping GAD, equipment data sheet, vendor drawing, etc.) have been reviewed by the concerned Owner’s specialist in approval/review code-2 or 1.
(ii)
To facilitate an overall systematic review the Contractor shall submit the design and drawings for each independent building/structure, together with a copy of the referenced reviewed input data, in one lot.
Submission of all identified documents including design calculations and drawings for review and/or information/record to the Owner/Owner’s representative by the Contractor shall be in requisite (as mentioned elsewhere) number of prints. To ensure accuracy, correctness and
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completeness of documents before submission to Owner/Owner’s representative, the Contractor shall ensure that all such submitted designs and drawings are complete in all respects, thoroughly checked, stamped APPROVED FOR CONSTRUCTION (AFC), and signed APPROVED by the Contractor's own responsible Civil/structural graduate (minimum) engineer (irrespective of the fact that the same are prepared in the Contractor's own design office or by an approved agency). Incomplete, unchecked, unsigned and unstamped documents/drawings and designs shall not be accepted for review/construction and shall be returned forthwith. 1.9
The accuracy/correctness of all designs and drawings shall be the sole responsibility of the Contractor and any delay/loss/damage incurred by the Owner in respect of any mistake/ discrepancy/anomaly in such designs and drawings shall be entirely borne by the Contractor.
1.10
Owner/Owner’s representative reserves the right to review any/all or none of the designs and drawings. Review by Owner/Owner’s representative shall not relieve the Contractor of his responsibility for correct design and execution of the works.
1.11
Revision of any design/drawing/detailing shall not be permitted unless the same is necessitated due to comments on review of such documents by Owner/Owner’s representative. Such revisions shall be restricted to incorporation of these comments only and no new details shall be added in the drawings unless called for by comments during review. All revisions shall be clearly marked and clouded for easy identification. Subsequent review of such revised documents shall be limited to revision as clouded.
1.12
All fabrication/erection drawings and bar bending schedules shall be prepared by the Contractor and shall be directly issued for construction to his work site. Requisite copies of such drawings shall, however, simultaneously be submitted to the Resident Construction Manager of Owner/Owner’s representative directly at Site, for his review and necessary action. Design calculations for all splices, joints and gusset plates shall also be submitted to the Resident Construction Manager, whenever asked for. The Resident Construction Manager, at his discretion, may review all or some or none of these designs & drawings. Wherever such review is carried out the same shall be restricted to the following: a) b) c)
1.13
Structural layouts, orientation, elevation of structural members. Section/size of members. Adequacy of few critical connections and joints for their required strength.
For analysis and design of structures usage of in-house developed software packages shall not be permitted. Internationally accepted commercial
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software viz. STAADPRO, COSMOS, GT STRUDEL, NISA only shall be permitted for analysis and design. STAAD shall not be allowed for use in dynamic analysis of machine foundations. 1.14
The following documentation as hard copy shall be submitted for computer aided analysis and design: (i) Complete print out of input and output files. (ii) Relevant sketches with node and member numbering, loading, etc. (iii) Summary of member end forces, support reactions, stress ratio, deflections, etc. Reviewing of designs/drawings is not obligatory on the part of Owner/Owner’s representative and complete correctness/soundness of the designs/drawings and their execution at the site shall be the sole responsibility of the Contractor irrespective of the fact whether the same has been reviewed by Owner/Owner’s representative or not. Any defect observed during construction or till the defect liability period of works' shall be rectified and removed by the Contractor. The Contractor shall carry out whatever modification or reconstruction is needed for the purpose, to the entire satisfaction of the Resident Construction Manager of Owner/Owner’s representative without any extra cost and/or time implication to the Owner.
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REFERENCED STANDARDS & PUBLICATIONS
Sl. No.
CODES
1.
Code of practice for plain & reinforce concrete
IS: 456
2.
Code of practice for general construction in steel
IS: 800
3.
Code of practice for use of steel tubes in general building
4.
Covered electrodes for manual metal arc welding
construction
IS: 806
of carbon and carbon manganese steel
IS:814
5.
Code of practice for use of metal arc welding for general construction
IS: 816
6.
Code of practice for design loads
IS: 875
7.
Fillers for expansion joints
IS: 1838
8.
Criteria for earthquake resistant design of structures
IS: 1893
9. 10.
Code of practice for structural use of unreinforced masonry Recommended practice for hot dipped galvanizing on iron and steel
IS: 1905 IS: 2629
11.
Methods for testing uniformity of coating of zinc coated articles
IS: 2633
12.
Code of practice for design & construction of raft foundations
IS: 2950
13.
Code of practice for earthquake resistant design and construction of buildings
IS:4326
14.
Code of practice for anti-termite measures in buildings`
IS: 6313
15.
Method for determination of mass of zinc coating
IS: 6745
16.
Chlorpyrifos emulsifiable concentrates
IS: 8944
17.
Criteria for design of steel bins for storage of bulk materials
IS: 9178
18.
Recommendations for metal arc welding of carbon and carbon manganese steel
IS:9595
19.
Two parts polysulphide based sealants
IS: 12118
20.
Code of practice for ductile detailing of reinforced concrete structures subjected to seismic forces
IS:13920
21.
Code of practice for structural safety of buildings - Shallow foundations
IS: 1904
22.
Code of practice for determination of bearing capacity of shallow foundations
IS:6403
23.
Code of practice for calculation of settlements of foundations
24.
Code of practice for cement and colored paints
Note
The above list is suggestive and not exhaustive. Apart from these basic codes any other related codes shall also be followed wherever required.
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IS: 8009(Pt I, II) IS: 5410
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DESIGN CRITERIA - GENERAL This specification defines the design criteria and loads that shall be taken in to account for the design of all structures and buildings. Pipe racks, Tower Structure (supporting stair, silo, bag filters, disengagement vessel, etc. at Crushed bath handling system), Platforms for access/maintenance, Sheds for electrical installations and Conveyor structure (from Silo To FTP) shall completely be of steel construction as per design/process requirements. Blower buildings shall be of RCC framed construction.
3.1
DESIGN LOADS
3.1.1
These loadings shall be applicable to all structures irrespective of the material employed for construction. a. Dead Loads The weight of all permanent construction including stairways, fixed service and other equipments excluding their content. b. Equipment Loads The empty weight of process equipment including all fixtures, platforms, ladders and attached piping but excluding contents shall be considered. If piping weight is not indicated separately or included in the weight of the equipment, the same shall be taken as 10% of the weight of the equipment. c. Live Loads Live loads shall, in general, be as per IS: 875. However, the following minimum live loads shall be considered in the design of structures: i.
iii.
viii.
ix.
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Technological Structure Operating area Maintenance area Service Platform Isolated platform (for valve operation) Access way Cross over Staircase Technological Structure Service platform Walkway
-
5.0 kN/m2 7.5 kN/m2
-
2.5 kN/m2
-
2.5 kN/m2 2.0 kN/m2
-
5.0 kN/ m2 2.5 kN/m2 - 3.0 kN/m2
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Live load on various types of roofs shall be as per the requirements given in IS:875. d. Operating Loads Operating loads shall comprise of the maximum design loads sustained by the equipments during plant operation. e. Wind Loads Wind loads shall generally be as per IS: 875. The basic wind speed of the site is taken as 50 m/s. Values of coefficients k1, k3 shall be as: k1 = 1.08 k3 = 1.0 Value of coefficient k2, as in IS: 875, shall be suitably taken for relevant class of structure with Category 2 terrain f. Seismic Loads Seismic forces shall be based on Seismic design basis (Doc. No. 1202-92554-0089 Rev 0) attached with this document. g. Impact & Vibratory Loads Structures subjected to impact or vibratory loads shall be designed as per the provisions of IS: 875 & IS: 2974. h. Soil and Hydrostatic Pressure Pressure on basement walls - In the design of basement walls or similar (approximately vertical) structures below grade, provision shall be made for resisting lateral pressure of the adjacent soil. If a portion or whole of the adjacent soil is below free water surface, pressure computations shall be based on the diminished weight of the soil (due to buoyancy) plus full hydrostatic pressure. Due allowance shall also be made for possible surcharges from fixed or moving loads. Effects of passive pressures mobilized due to earthquakes shall also be taken into account where required in the design of pits, basement walls etc. Uplift on Floors - In the design of basement floors and similar (approximately horizontal) constructions below grade, the upward pressure of water shall be taken as full hydrostatic pressure applied over the entire plan area. The hydrostatic head shall be measured from the underside of construction. The downward load due to over burdens shall be calculated only for the volume over projected plan area (i.e.,
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the volume of overburden beyond projected plan area shall not be considered). Factors of safety against uplift shall be 1.2. i. Other Loads Apart from the specified live loads, any other equipment load or possible overloading during construction/hydro-test/ maintenance/erection shall also be considered in the design. Under hydro test condition the wind force shall be taken as 25% of normal loading. Design of all structures shall also consider any other relevant and consequential load/stress imparted to the structure. All liquid retaining/storage structures shall be designed assuming liquid up to the full height of wall irrespective of provision of any over flow arrangement. Pressure relief valves or similar pressure relieving devices shall not be made in underground water retaining/storage RCC structures. All buildings and structures shall be checked and designed to satisfy the worst load combination that produces maximum forces and effects and consequently maximum stresses. Wind and earth quake loads shall not be considered to act simultaneously.
3.2
SOIL INFORMATION FOR FOUNDATION DESIGN For soil information reference shall be made to the Geo-technical Data/recommendations. The grade of concrete, minimum cement content and water cement ratio (for concrete) to be used in foundation shall in general be as per the philosophy adopted for the entire structure. However, if Geo-technical recommendations require a higher cement content and/or specified type of cement, the Geo-technical recommendations shall have precedence. Any other remedial actions required for foundations due to aggressiveness of sub soil water shall be as per the Geo-technical recommendations.
3.3
ANTI-TERM ITE TREATMENT Anti-termite treatment shall be provided for habitable areas.
3.4
FOUNDATIONS
3.4.1
NGL (Natural ground level) and FGL (Finished ground level) shall be marked on all drawings showing foundation/sub-structure details and related design documents.
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3.4.2
Equipment foundations shall be separated from adjoining parts of floor/pavement slabs. Joints at floor/pavement slabs shall be suitably sealed.
3.4.2
Safe bearing pressure (allowable net safe bearing capacity) shall be based on the following minimum criteria under Dead Load + Live Load (or with Operating) condition: Foundations for structures supporting process equipments and piping.
25mm settlement.
Buildings
40mm settlement
For transient loadings viz. with wind/seismic loads, settlement shall not be the criteria and safe bearing capacity based on shear criteria shall be considered. 3.4.6
Structures supported on RCC strip footings shall be provided with suitable tie beams connecting all footings at foundation level. Minimum width of footing shall be 1000 mm.
3.4.7
Raft foundations shall be designed as per IS: 2950.
3.4.8
Masonry walls shall be supported on continuous plain cement concrete mats/plinth beams. Top of plinth beams shall be located minimum 300mm below the finished grade level. Fouling of plinth beams with cable trenches, drains, pipe ducts, service lines etc. shall not be acceptable.
3.4.9
Factors of safety for the design of foundations shall be as per Enclosure-I of this section.
3.4.10
For the design of foundations for vertical vessels and process columns under hydro test condition minimum 25% wind load shall be considered acting on the equipment.
3.4.11
All foundations shall rest minimum 1.0 metre below the Natural Ground Level or Finished Grade Level, which ever is lower. Factors of safety against overturning and sliding shall be as per values given in ENCLOSURE-I. Component of soil backfill weight over foundation slab shall be appropriately covered as foundation dead load. For stability checks the weight of soil as overburden shall be as per ENCLOSURE-I.
3.4.12
The design ground water level shall be as per the Geo-technical specifications/report/data and the hydrostatic pressure there from, shall be adequately accounted for in the design. In addition, all possible combinations of lateral soil pressures, hydrostatic pressures, uplifts, surcharges from fixed/moving loads etc shall be considered in the design. In unconsolidated, filled-up areas, foundation designs shall be based on net soil pressure diagrams only.
3.14.13
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3.4.14
Permissible increase in SBC (for compressive, shear and uplift/tension) shall be as per relevant BIS codes if not otherwise mentioned in the Geotechnical recommendations.
3.5
FLOORING DETAILS FOR BUILDINGS The specifications given hereunder shall be adopted for the non-suspended ground floor slabs for buildings . Sub-base of flooring shall be comprised of 200mm thick sand layer compacted to 85 % relative density laid over compacted (compacted to 95 % dry density) earth fill base. Strl non-suspended slab in M 20 Grade concrete (Reinforced with 8mm dia bars @200 c/c both ways & centrally placed) shall be cast over 50mm thick 1:5:10 grade lean concrete placed on underlaying sand layer. Floor finish shall be as per Architectural specifications furnished in the tender document..
3.6
SPECIAL CONSIDERATIONS FOR REINFORCED CEMENT CONCRETE (RCC) STRUCTURES AND FOUNDATIONS
3.6.1
General/Design Methods -
All buildings, structures, foundations, machine/equipment foundations, liquid retaining/storage structures, pipe/cable trenches, pits etc. shall be designed based on the latest revision of referenced BIS Codes in general and other relevant BIS Codes as applicable. It shall be ensured that the skin temperature of concrete at no time exceeds 800 C.
-
The minimum cement content and the maximum water-cement ratio for concrete in superstructures as well as foundations shall be as given in Table-2.
-
All structures shall be of frame-type construction. Where ever required detailing shall be as per provisions of IS: 13920.
-
Unless otherwise specified elsewhere in this document only Limit state method as per IS: 456 shall be followed in the design.
-
All machine/equipment foundations, cable/pipe trenches shall be of RCC construction only. Cable/pipe trenches shall be suitably sloped and adequate provision shall be made for draining out of accumulated water to nearest manholes/pits.
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-
Where the specified design depth of ground water table so warrants, all underground pits, tunnels, basements, cable trenches etc. shall be of leak-proof RCC construction.
-
Foundations placed at varied depths shall be designed considering bearing capacity at that particular level with due consideration of an uplift/subsoil water table.
-
Intermixing of different grades of concrete and/or cement in the same structure/structural element shall not be accepted.
-
Intermixing of different grades of steel (main reinforcement) in the same structure shall not be accepted.
-
RCC pits, tanks etc. for storage of corrosive liquids shall be provided with suitable anticorrosive treatment/lining.
-
RCC storage/process tanks located above floor or roof shall not rest directly on slab/beam but shall have independent supporting structures, which in turn shall rest on (primary or secondary) beams and/or columns.
Type Cement
of
Plain Concrete
Reinforced Concrete
Minimum Maximum Cement Content Water(kg/m3) Cement 43 Grade OPC/ Ratio PPC/PSC 220
0.6
Minimum Cement Content (kg/m3) 300
Maximum WaterCement Ratio 0.55
Note: Grade of concrete is based on NALCO’s advice from feedback of good performance of M-20 grade concrete in existing plant.
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3.6.2
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Reinforcement bars High strength deformed steel bars of grade Fe 415 conforming to IS: 1786 shall be used.
3.6.2.1
Minimum Cover to Main Reinforcement The following minimum clear cover shall be provided for RCC works. -
Slab (roof & floor), Canopy Cantilever, Waist slabs
-
Beam (roof, floor & tie), Lintel.25mm or dia of bar whichever is greater
-
Column
40mm
-
Column Pedestal
50mm
-
Retaining Wall, Basement and Pit Wall. a) Face in contact with earth: 40mm b) Free face: 25mm or dia of bar whichever is greater -
3.6.3
25mm or dia of bar whichever is greater
Foundation slab, base slab, plinth beam 50mm
Minimum Thickness of Structural Concrete Elements The following minimum thickness shall be followed: -
Footings (All types including raft foundations without beams) 300mm (Note: Tapered footings shall not have thickness less than 200mm at the edges. Minimum average thickness shall not be less than 300mm)
-
Slab thickness in Raft foundations with beam & slab construction
150mm
-
Floor/Roof Slab, Walkway, Canopy Slab resting on beams
125mm
-
Cable/Pipe Trench/Launder Walls & Base Slab
100mm
-
Parapet/Cantilevered Canopy Slab
100mm
-
Underground Pit/Reservoir walls Base slab with beam Base slab without beam
150mm 200mm 300mm
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3.6.4
Minimum Height of Pedestals The minimum projection of pedestals supporting any steel structure/stanchion bases shall be 300/150mm above the high point of pavement/ finished grade/finished floor level whichever is higher, for outdoor and indoor located pedestals respectively. The maximum projection of pedestals for staircase/ladder shall be 200mm.
3.6.5
Minimum Cover to Foundation Bolts Minimum distance from the centerline of foundation/anchor bolt to edge of pedestal shall be the maximum of the following: i) ii) iii)
3.6.6
Clear distance from the edge of the base plate/base frame to the outer edge of the pedestal shall be minimum 50mm. Clear distance from the face of pocket to the outer edge of the pedestal shall be 75mm. Clear distance from the edge of the sleeve or anchor plate to the edge of pedestal shall be 75mm.
Concrete Mix a) Reinforced Cement Concrete (RCC) Unless otherwise noted, reinforced concrete conforming to IS: 456 shall be used using 20mm and down size graded crushed stone aggregate. The minimum grade of reinforced cement concrete to be used for superstructures and foundations shall be M20 (subject to confirmation for use of lesser grade of concrete in foundations based on aggressiveness of soil/ground water as established from soil investigation report b) Lean Concrete Mudmat of minimum 75mm thickness of lean concrete mix 1:5:10 (by weight, using 40mm and down size grade crushed stone aggregate) shall be provided under all RCC. Mudmat shall extend 75 mm on all sides beyond the edges of base slabs in case of liquid retaining/storage structures and 50 mm in case of other foundations. The exposed surface of mudmat layer in case of liquid retaining/storage structure shall be finished smooth. Lean concrete of grade 1:5:10 (by weight) shall be used as filler material wherever loose subgrade exists by removing the loose soil/fill. c) Plain Cement Concrete (PCC)
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Plain cement concrete mud mat of grade M15 (by weight) of minimum 150mm thickness (using 40mm and down size graded crushed stone aggregate) shall be provided under all masonry wall foundations. Plain cement concrete of grade M 20 (by weight) of minimum 40mm thickness (using 10mm & down size graded aggregates) shall be provided as damp proof course at plinth level of all masonry walls. Making-up of levels for placing the foundation at a shallower depth from the NGL/FGL (from that as specified in the Geo-technical recommendations) by means of filling of lean concrete is not acceptable. 3.6.7
Grouting & Minimum Grout Thickness The minimum thickness of grout shall be 25 mm. All anchor bolt sleeves/pockets and spaces under column bases, shoe plates etc. shall be grouted with free flow, non-shrink (premix type) grout with 28-day minimum cube crushing strength of 40N/mm2. Ordinary cement sand (1:2) grout shall only be used under the base plates of crossover, short pipe supports (not exceeding 1.5 m height) and small operating platforms (not exceeding 2.0m in height) not supporting any equipment. Neat cement shall not be used for grouting under any condition. Grouting requirement for machines and equipments are not covered here.
3.6.8
Movement Joints Expansion and/or separation joints in non-suspended ground floor slab shall be filled with sand for the full depth of slab except the top 12mm which shall be filled up with approved two part liquid polysulphide sealing compound conforming to IS: 12118. Joints in basement slabs shall be made leak proof by providing PVC water stops. Joints in the super-structure shall be provided by means of gap between two consecutive structural members. The gap shall be based on the design requirements and shall be treated to a minimum as under: a)
When the vibrating equipment is separately supported on a structure, a clear air gap shall be provided between the vibrating equipment supporting structure and the surrounding floor with provision of suitable moulding/ kerb to stop any leakage/ overflow of any floor wash to the next lower floor.
b)
In normal floors, expansion and/or separation joints shall be covered both on top and bottom with 3mm thick Aluminium sheet fixed on both sides of the joint with brass screws. Provision of movement on one side shall be kept with proper slotted holes. Similar cover plates shall be provided for all exterior columns on both interior and exterior faces. The edges of these plates shall be properly
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chamfered. Bitumen impregnated fibre board (as per IS:1838) shall be used between the gap of the two members on either side of the joint for the full depth in such movement joints. The top 12mm depth shall be filled up with two part liquid polysulphide sealing compound (as per IS:12118).
3.7
SPECIAL CONSIDERATIONS FOR STEEL STRUCTURES
3.7.1
General Structural steel work shall include the following structures in general, but not limited to: -
Steel buildings/open structures Tower structure Shed Conveyors Platforms & walkways Ladders, staircases & hand railing Pipe racks/pipe supports/cable racks Crane gantry girders & monorails
Design, fabrication and erection of the above work shall be carried out in accordance with the following IS Codes as applicable to the specific structures, viz. IS: 800, 806, 814, 816, 875, 1893, 9178, 9595, 6533, etc. Basic consideration of structural framework shall primarily be stability, ease of fabrication/erection and overall economy satisfying relevant Indian Standard Codes of Practice. Simple and fully rigid design as per IS: 800 shall be used. Where fully rigid joints are adopted they shall generally be confined to the major axis of the column member 3.7.2
Steel Grade Structural steel shall be of yield stress of 250 MPa conforming to Grade A of IS: 2062.
3.7.3
3.7.4
Limiting permissible Stresses -
Permissible stresses in bolts shall be as specified in: IS: 800 Hot rolled sections
-
Permissible stresses in welds shall be as specified in: IS: 816 Hot rolled sections
Limiting Deflection a) The limiting permissible vertical deflection for structural steel members shall be as specified below:
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- Gantry girder for electric overhead crane (Capacity upto 50T)
:
L/750
- Gantry girder for electric over head crane (Capacity over 50T)
:
L/1000
- Gantry girder for manually operated crane
:
L/500
- Girder/beam for supporting dynamic equipment/hoist : L/450 - Grating/Chequered plate : L/200 or 6mm whichever is minimum. - Purlins supporting any type of roofing material under (dead load+live load) or (dead load+wind load) conditions : L/200 - Other structures/structural components:As specified in relevant IS Codes Where 'L' represents the span. b) The limiting permissible horizontal deflection for steel structure/ building shall be Height/325. 3.7.5
Design Criteria
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-
Basic consideration of structural framework shall primarily be stability satisfying relevant Indian Standard Codes of Practice and specifications given herein.
-
Simple and fully rigid design as per IS: 800 shall be used. Where fully rigid joints are adopted they shall be confined to the major axis of the column member.
-
Structural elements continuously exposed to temperatures above 2000 C shall be designed for reduced stress as per Table 4 of IS: 6533 (Part 2). The expected temperature of steel components shall not be allowed to exceed 4000 C.
-
No rigid connections shall be used to connect structures to equipments, e.g. columns, vessels, heaters etc., which have high working temperatures.
-
Crane gantry girders shall be of welded construction and of single span lengths. Splicing in gantry girders will not be permitted. Chequered plate shall be used for gantry girder walkway flooring.
-
All steel staircases for main approaches to operating platforms, shall have channels (minimum size MC150) provided as stringers with DOCUMENT TITLE
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minimum clear width of 1000 mm and slope of 41 degrees. The vertical height between successive landings shall not be less than 2.6 metres, nor exceed 4.0 metres. Treads shall be minimum 230mm wide made of grating (with suitable nosing) spaced equally so as to restrict the rise to maximum 200mm. Steel staircases for crossovers, shall have a minimum width of 750 mm. -
Ladders shall be provided with safety cages when the top of the ladder is more than 4.5m above the landing level. Safety cages shall start 2.5 metres above the lower landing level. Ladders shall be of 450mm clear width with 20mm diameter MS rungs spaced at 300mm (maximum). Ladders shall preferably be vertical. In no case shall the angle with the vertical exceed five degrees. -
Handrails, 1000mm high, shall be provided to all walkways, platforms, and staircases. Toe plate (100mmx5mm) shall be provided for all hand railing (except for staircases). Spacing of uprights shall be 1500mm (maximum). Two types of hand railing shall be provided. a) b)
-
For walkways, platforms (except platform supported on vessels), staircases: Top rail, mid rail and upright shall be 32 (M) NB MS tubes. For platforms supported on vessels: Top rail shall be 32 (M) NB MS tubes but mid rail (50 x 6 flat) and upright (Angle 50 x 50 x 6) shall be of structural steel.
MS Gratings shall be welded and minimum 25 mm deep. All gratings shall be fabricated as per the standard and shall confirm to Type-II or III (based on application). The minimum weld length shall be as per IS: 816. Deflection shall not be more than 6mm or span/200, which ever is lower. The acceptance criterion for welded gratings shall be as follows: The joint shall be able to sustain a minimum pullout load of 1.5 times the allowable shear capacity of the secondary member. Projection of secondary member above the main member shall not be more than 1.5mm. -
Welded connections shall be adopted in general, except for isolated cases where bolted connections are specifically allowed with prior permission from Owner/Owner’s representative. All permanent and erection connections shall have at least two 20mm diameter and 16mm diameter bolts respectively.
-
All connections shall be designed for full moment carrying capacity of the connecting members together with 60% full shear carrying capacity for sections with depth 200mm and above and 50% full shear carrying capacity for sections with depth less than 200mm or for the actual design forces, whichever is more.
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-
All fabricated structures shall be given one shop coat of primer compatible with the final painting. The final painting of steel surfaces shall be done as per specifications included elsewhere in this bid package.
-
Minimum two nuts shall be used for all anchor bolts.
-
Gusset plates of different thickness shall not be used in the same truss or girders. Gusset plates for all bracing shall be of same thickness as that used for truss/girders unless a higher thickness is required by design.
-
The cladding/ roofing for any steel shed structure shall consist of 20 gauge profiled Aluminium sheet in roof and 22 gauge profiled Aluminium sheet in sides.
3.7.6
Minimum Thickness
3.7.6.1
The minimum thickness of various structural components sections) shall be as given:
(Hot rolled
General Construction: Trusses, purlins, side girts & bracings Columns, beams Gussets in trusses & girders i) Upto and including 12m span ii) Above 12m span Stiffeners Base plates Chequered plate Grating
6mm 7mm 8mm 10mm 8mm 10mm 6mm(on plain) 3mm
The minimum thickness of structural components (except gratings & chequered plates), which are directly exposed to weather and inaccessible for repainting, shall be 8mm . Note: The minimum thickness for rolled beams and channels shall be mean flange thickness regardless of the web thickness. 3.7.6.2 3.7.6.3
3.8
SMELTER DIVISION
The minimum thickness of tubes shall be as specified in IS: 806. Structural members exposed to marked corrosive action shall be increased in thickness or otherwise suitably protected against corrosion.
SPECIAL CONSIDERATIONS FOR MASONRY WORKS
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3.8.1
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General All masonry works shall be designed in accordance with IS: 1905, IS: 1597, IS: 2185, IS: 4326 and other relevant IS Codes as applicable. All external brick, stone and hollow concrete block masonry walls shall be of minimum 230, 350 and 250mm thickness respectively. Bricks for masonry work shall be of class 5.0 conforming to IS: 1077. Hollow concrete blocks shall conform to IS: 2185.
3.8.2
Cement Mortar All masonry work shall be constructed in 1:6 cement sand mortar except half brick partition walls which shall be constructed in 1:4 cement sand mortar with two numbers of 6mm diameter MS bars provided at every fourth course properly anchored with cross walls or pillars.
4.0
DESIGN REQUIREMENTS FOR SPECIFIC APPLICATIONS
4.1
PIPE RACK For designing the pipe rack superstructure and foundation the following loads shall be considered. Vertical Loading: Actual weights of pipes coming at each tier shall be calculated. In calculating the actual weight of pipe, the class of pipe, material content and insulation, if any, shall be taken into consideration. Insulation density shall be taken as 2600N/m3 minimum. In case of gas/steam carrying pipes, the material content shall be taken as one-third volume of pipe filled with water. The total actual weight thus calculated shall then be divided by the actual extent of the span covered by the pipes to get the uniformly distributed load per unit length of the span. To obtain the design uniformly distributed load over the entire span, the u.d.l. obtained as above and shall be assumed to be spread over the entire span. However minimum loading for any pipe rack shall not be less than 1.25kN/m2. In case, the calculated loading is higher than 1.25kN/m2, this shall be rounded off to the nearest multiple of 0.25 (i.e. 1.50, 1.75, 2.0kN/m2). Vertical loads of flare pipes shall be taken as one-third full of water for Process Unit piping and one-sixth full for Off site piping. Friction Force (Longitudinal & Transverse) Where the pipes are of similar diameter and service conditions, the friction force at each tier on every portal both in longitudinal and transverse directions shall be 10% of the design vertical loading of the pipes for four or more pipes supported on a tier, and 30% of the design vertical loading of the pipes for single to three pipes supported on a tier. Longitudinal friction
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force shall be considered as uniformly distributed over the entire span of the beam at each tier and transverse friction force shall be considered as a concentrated load at each tier level. Friction force on T-supports and trestles shall be taken as 30% of the vertical loading in longitudinal direction and 10% of vertical loading in transverse direction acting simultaneously, and vice versa. Both longitudinal and transverse friction forces shall be considered to be acting simultaneously. For two-phase fluid flow/transfer lines the frictional force shall be minimum 50% of the weight of pipe including contents and insulation, acting simultaneously in tranverse and longitudinal directions. -
Anchor and Guide Force (Thermal load) a) Longitudinal → As per piping inputs. b) Transverse → As per piping inputs.
Wind Force Transverse wind loading shall be calculated depending on the width of the Pipe Rack as follows: a) Basic wind pressure shall be considered as per IS: 875 with wind speed as given in this document b) To calculate wind load in transverse direction of piperack, a projected height of 1.25m/1.5m/2.0m shall be considered on all tiers irrespective of height between two tiers, of rack widths of 4m/6m/greater than 6m and upto 10m respectively. For piperacks of widths greater than 10m, the above projected height shall be taken as 0.8[diameter of largest pipe including insulation (m)] + tan 10°[width of rack (m)]. However, this shall not exceed the height between consecutive tiers. c)
For flare header or any other line supported on extended leg of piperack, the wind force shall be considered separately.
Loading on Longitudinal Beams Longitudinal beams connecting portal columns shall be sufficiently strong to sustain a minimum of 25% of the load on the transverse beams. This total load shall be assumed as two equal concentrated loads acting at 1/3rd span. This load shall be in addition to the piping loads transferred from the intermediate beams. Other longitudinal axial forces coming on it from the design of the supporting system shall also be simultaneously taken into account in the design of the longitudinal beam. Friction & Anchor Forces, if specifically given by the Piping Specialist shall also be catered for in the design. Loads from monorails, when supported from these beams, shall also be considered to be acting simultaneously along with all other loads mentioned above. Cable Tray and Walkway Loads
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The estimated actual load from electrical, instrumentation trays shall be considered at the specified locations, together with walkways, if provided. Earthquake Force Calculations for forces due to earthquake shall be based on IS:1893 4.2
CONVEYOR For conveyor structure and supporting system Document No. 1202-00-16-48DB253 (enclosed with the tender document) shall be referred.
4.3
PAINTING All painting and colour coding for structural steel works shall be done as per painting specifications included elsewhere with this bid package.
4.4
STRUCTURAL ARRANGEMENTS FOR MAINTENANCE WORKS
Structural arrangements supporting monorails for the removal of equipments/parts of the equipments shall be provided to facilitate maintenance of equipments on grade / technological structures.
5.0
MATERIAL REQUIREMENTS
5.1
General The minimum requirements of various materials to be used in Civil and Structural works are as:
5.2
WATER
5.2.1
Water used in construction for all civil & structural works shall be clean and free from injurious amounts of oil, acids, alkalis, organic matters or other harmful substances which may be deleterious to concrete, masonry or steel. The pH value of water sample shall be not less than 6. Potable water will be considered satisfactory. All requirements of IS: 456 have to be met.
5.2.2
Tests on water samples shall be carried out in accordance with IS: 3025 and these shall fulfill all the guidelines and requirements given in IS: 456.
5.2.3
Water for curing shall be of the same quality as used for concreting and masonry works.
5.3
AGGREGATE (FOR CONCRETE)
5.3.1
General
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- Coarse and fine aggregates for Civil and Structural Works shall conform in all respects to IS: 383 (Specification for coarse and fine aggregates from natural sources for concrete). Aggregates shall be obtained from an approved source known to produce the same satisfactorily. Aggregates shall consist of naturally occurring (crushed or uncrushed) stones, gravel and sand or a combination thereof. These shall be chemically inert, hard, strong, dense durable, clean and free from veins, adherent coatings, injurious amounts of alkalis, vegetable matter and other deleterious substances such as iron pyrites, coal, lignite, mica, shale, sea shells etc. - Aggregates, which may chemically react with alkalis of cement or might cause corrosion of the reinforcement, shall not be used. - The maximum quantities of deleterious materials in the aggregates as determined in accordance with IS:2386 - Part II (Methods of Test for aggregates for concrete), shall not exceed the limits defined in IS:383. 5.3.2
Coarse Aggregates - Coarse aggregates are the aggregates, which are retained on 4.75mm IS Sieve. It shall have a specific gravity not less than 2.6 (saturated surface dry basis). -
5.3.3
These may be obtained from crushed or uncrushed gravel or stone and may be supplied as single sized or graded. The grading of the aggregates shall be as per IS: 383 or as required by the mix design, to obtain densest possible concrete.
Fine Aggregates - Fine aggregates are the aggregates which pass through 4.75mm IS sieve but not more than ten percent (10%) pass through 150 micron IS sieve. These shall comply with the requirements of grading zones I, II and III of IS: 383. Fine aggregates conforming to grade zone IV shall not be used for reinforced concrete works. - Fine aggregates shall consist of material resulting from natural disintegration of rock and which has been deposited by streams or glacial agencies, or crushed stone sand or gravel sand. Sand from sea shores, creeks or riverbanks affected by tides, shall not be used for filling or concrete works.
5.3.4
Sampling and Testing The Contractor shall carry out all tests including mix designs of concrete, at the start of work as well as during any stage of construction as per the requirement. Tests shall be carried out in accordance with IS: 516-Methods of test for strength of concrete and IS: 2386-Methods of test for aggregates
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for concrete. The method of sampling shall be in accordance with the requirements given in IS: 2430. 5.3.5
Storage of Aggregates -
-
Storage of all types of aggregates at the site of work shall be as specified in IS: 4082. Aggregates shall in no case be stored near excavated earth or directly over ground surface Fine aggregates delivered at the site in wet condition or becoming wet due to rain or any other means, shall not be used for at least 24 hours. For the use of such aggregates the contractor shall adjust the water content in accordance with IS: 2386 to achieve the desired mix.
5.4
SAND (FOR MASONRY & FILLING)
5.4.1
Sand for Masonry Mortars -
The sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a combination of any of these. The sand shall be hard, durable, clean and free from adherent coatings and organic matter and shall not contain the amount of clay, silt and fine dust more than specified in IS: 2116.
-
The sand shall not contain any harmful impurities such as iron pyrites, alkalis, salts, coal or other organic impurities, mica, shale or similar laminated materials, soft fragments, sea shells in such form or in such quantities as to affect adversely the hardening, strength or durability of the mortar.
-
The maximum quantities of clay, fine silt, fine dust and organic impurities in the sand, when tested in accordance with IS: 2386, shall not be more than 5% by mass in natural sand, or crushed gravel sand or crushed stone sand. For organic impurities, when determined in accordance with IS: 2386, colour of the liquid shall be lighter than that indicated by the standard solution specified in IS: 2386.
5.4.2
Grading of Sand The particle size grading of sand for use in mortars shall be within the limits as specified below: GRADING OF SAND FOR USE IN MASONRY MORTARS
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IS SIEVE DESIGNATION IS:460 (PART I)
PERCENTAGE REF. TO METHOD PASSING BY MASS OF IS:2386(Part I)
4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron
100 90 to 100 70 to 100 40 to 100 5 to 70 0 to 15
In case of sand whose grading falls outside the specified limits due to excess or deficiency of coarse or fine particles, this shall be processed to comply with the standard by screening through a suitably sized sieve and/or blending with required quantities of suitable sizes of natural sand particles or crushed stone screening which are by themselves unsuitable. The various sizes of particles of which the sand is composed shall be uniformly distributed throughout the mass. 5.4.3
Sampling and Testing The method of sampling shall be in accordance with IS: 2430. The amount of material required for each test shall be as specified in relevant parts of IS: 2386. All tests shall be carried out in accordance with the relevant parts of IS: 2386. If further confirmation as to the satisfactory nature of the material is required, compressive test on cement mortar cubes (1:6) may be made in accordance with IS:2250 using the supplied material in place of standard sand and the strength value so obtained shall be compared with that of another mortar made with a sand of acceptable and comparable quality.
5.4.4
Sand for Filling Sand for filling shall meet the requirements of IS: 383 and shall be natural sand, hard, strong, free from any organic and deleterious materials. Sand obtained from seashores, creeks or riverbanks affected by tides, shall not be used for filling. Fine aggregates suitable for concreting works shall be suitable for filling also. No sand below grading zone-III as per IS: 383 shall be allowed for filling.
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5.5
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CEMENT Unless otherwise specifically called for, cement for concrete works shall be one of the following: 43 grade ordinary Portland cement Rapid hardening Portland cement Portland slag cement Portland Pozzolana cement (fly ash based) Portland Pozzolana cement (calcined clay based) Sulphate resisting Portland cement High alumina cement Supersulphated cement
RCC and PCC/lean IS: 8112 IS: 8041 IS: 455 IS: 1489 (Part-1) IS: 1489 (Part-2) IS: 12330 IS: 6452 IS: 6909
For masonry applications the use of Masonry cement (conforming to IS: 3466) can be made. 5.6
STEEL
5.6.1
General All steel bars, sections, plates, and other miscellaneous steel materials, etc. shall be free from loose mill scales, rust as well as oil, mud, paint or other coatings. The materials, construction specifications such as dimensions, shape, weight, tolerances, testing etc., for all materials covered under this section, shall conform to respective BIS codes.
5.6.2
Reinforcement Bars High strength Deformed Steel bars of minimum grade Fe 415, conforming to IS: 1786 shall be used.
5.6.3
Structural Steel Structural steel to be used for general structural purposes shall be of Grade-A conforming to IS: 2062. Other structural steel sections shall conform to following BIS codes: Steel tubes for structural purposes.
IS: 1161
Mild Steel Tubes, tubular and other wrought steel fittings.IS: 1239 Steel for general structural purposes (Grade A).
SMELTER DIVISION
IS: 2062
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5.6.4
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Miscellaneous Steel Materials
Miscellaneous steel materials shall conform to the following BIS codes: Expanded Metal Steel Sheets for General purposes IS: 412 IS: 432 Specification for mild steel and medium tensile steel bars and hard drawn steel wire for concrete reinforcement (Grade I) (For mild steel bars of anchor bolts, rungs, metal inserts, grating etc.) Hexagonal head bolts, screws & nuts of product Grade C. Technical supply conditions for threaded steel fasteners
IS: 1363 IS: 1367
Plain washers
IS: 2016
Mild Steel Tubes, tubular and other wrought steel fillings. (For Hand rail tubular sections).
IS: 1239
Steel chequered plates.
IS: 3502
Hexagonal bolts and nuts (M42 to M150).
IS: 3138
5.6.5
Anchor Bolts Material for Anchor Bolts such as MS bars, washers, nuts, pipe sleeves and plates etc. shall be as per relevant BIS codes mentioned above under Clauses 5.6.4.
5.7
BRICK
5.7.1
General Bricks for masonry works shall conform to IS: 1077 - Specification for common burnt clay building bricks and shall be of class 5.0 (with minimum compressive strength of 7.5 N/mm2). Physical requirements, quality, dimensions, tolerances etc. of common burnt clay building bricks shall conform to the requirements of IS: 1077. Bricks shall be hand-moulded or machine-moulded and shall be made from suitable soils. The bricks shall have smooth rectangular faces with sharp corners and shall be well burnt, sound, hard, tough and uniform in colour. These shall be free from cracks, chips, flaws, stone or humps of any kind. Testing of the bricks shall be done as per IS: 5454 and IS: 3495. Water absorption shall not be more than 20% by its dry weight when soaked in cold water for 24 hours. Locally available bricks of non-modular size in place of bricks of modular size can be used in case the bricks satisfy the other requirements of IS: 1077 (class 5.0).
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5.8
ADMIXTURES
5.8.1
General Requirements for Admixtures All concrete admixtures shall comply with the following Indian standards: Specification for integral cement water proofing compounds.
IS: 2645
Specification for other admixtures for concrete.
IS: 9103
In case of non-availability of any IS code for testing and acceptability criteria, relevant American, British or German Code shall be applicable.
5.8.2
-
No admixture shall impair the durability of the concrete, nor combine with the ingredients to form harmful compounds, nor increase the risk of corrosion of reinforcement. Use of admixtures shall not reduce the dry density of concrete. Once the proportion of admixtures have been established, strict check shall be maintained not to alter the proportions of ingredients and water-cement ratio of the Design Mix during execution.
-
The chloride contents in admixtures shall not exceed 2% by mass of the admixture or 0.03% by mass of the cement.
-
Admixtures, which do not meet the requirements stipulated in this document, shall not be used.
Water Proofing Compounds The permeability of the specimen with the admixture shall be less than half of the permeability with a similar specimen without the use of these compounds. These compounds shall be used in such proportion as recommended by manufacturer but in no case it shall exceed 3% by weight of cement. The initial setting time of the cement with the use of these compounds shall not be less than 30 minutes and final setting time shall not be more than 10 hours. Tests shall be carried out in accordance with IS: 4031. Compressive strength of the specimen at 3 days shall not be less than 160kg/cm2 nor 80% of the 3 days compressive strength of mortar cubes prepared with same cement and sand only, whichever is higher. Similarly compressive strength at 7 days shall not be less than 220 kg/cm2 nor less than 80% of the 7 days compressive strength prepared with the same cement and sand only, whichever is higher. The test to determine the compressive strength shall conform to IS: 4031.
5.9
BITUMEN/BITUMINOUS MATERIALS
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Bitumen to be used for various types of work shall meet all the requirements of relevant BIS codes as given below: Specification of Paving Bitumen.
IS: 73
Specification for bitumen mastic for floorin(Grade IV) Specification for Bitumen felts for water proofing and damp proofing.
IS:1195 IS: 1322
Specification for Bituminous compounds for water proofing and caulking purposes. Specification for preformed fillers for expansion joint in concrete pavements and structures.
IS:1834 IS: 1838
Specification for bitumen mastic for use in water proofing of roofs Specification for bitumen primer for use in water proofing and damp proofing.
IS:3037 IS: 3384
Specification for Bitumen Mastic for Tanking and Damp proofing. Specification for Glass fibre base coal tar pitch & bitumen felts Code of practice for damp proofing using bitumen mastic
IS:5871 IS: 7193 IS: 7198
Specification for bitumen Mastic, Anti Static and electrically conducting grade.
IS: 8374
Tests and acceptable criteria shall be as per relevant BIS codes. 5.10
PVC PIPES PVC Pipes shall conform to the requirements of IS: 4985.
5.11
ANTI-TERMITE COMPOUNDS
5.11.1
Chloropyrifos emulsifiable concentrates (1%) conforming to IS: 8944 shall be used for treatment of soil for protection of buildings against attack by subterranean termites.
5.12
POLYSULPHIDE SEALANTS
5.12.1
All Polysulphide Sealants shall conform to IS: 12118. Test conditions and requirements shall be as given in the above referred BIS code.
6.0
CONSTRUCTION REQUIREMENTS
6.1
CONSTRUCTION
6.1.1
All concrete works shall be carried out as per the provisions of IS: 456 and other relevant IS Codes. Concrete Mix Proportioning and Design Mix; Sampling and Strength test of Concrete; Testing of Structures, Production and Control of Concrete tolerances and placing of reinforcement and for cover; Transporting, Placing, Compacting and Curing etc., shall be as specified in IS: 456.
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6.1.2
The damp proof course shall be laid in two layers of equal thickness and each layer given two coats of hot bitumen on top (grade A90/S90 conforming to IS:73) at the rate of 1.7 kg/m2. Dry sharp sand shall be sprinkled evenly over the top layer of bitumen before hardening.
6.1.3
Formwork and stripping of formwork shall be as per the provisions of IS: 456.
6.1.4
Assembly of reinforcement in RCC structures shall conform to IS: 456.
6.1.5
Fabrication of all structural steel works shall be carried out as per the provisions of IS: 800/806 and other relevant BIS codes. Fabrication shall include cleaning, straightening, cutting, bending, holding, bolting, welding, machining, painting, marking, assembling, erecting, inspecting and testing etc.
6.1.6
Erection of all structural steel works including supply of plant & equipment, storing and handling, setting out, field connections, field welding and security during erection shall conform to IS: 800/806.
6.1.7 All masonry works shall be carried out as per the provisions of IS: 1597/2212/4326 and other relevant BIS codes. 6.1.8
The limits of dimensional tolerances for all works shall be as given below: For Plain and Reinforced Cement Concrete Structures: (a) Deviation from specified dimensions of cross section of columns and beams.
- 6mm to +12mm
(b) Deviation from dimensions of footings (See Note below):
Note:
(i)
Dimensions in plan
-12mm to +50mm
(ii)
Eccentricity
0.02 times the width of the footing in the direction of deviation but not more than 50 mm.
(iii)
Thickness
+0.05 times the specified thickness.
Tolerances apply to cast-in-situ concrete dimensions only, not to positioning of vertical reinforcing steel or dowels. (c) Deviation in length (major dimension of single unit): Up to 3m
SMELTER DIVISION
+6mm
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3m to 4.5m
+9mm
4.5m to 6m
+12mm
Additional deviation for every subsequent 6m
+6mm
(d) Deviation in straightness or bow (deviation from specified line) for a single or continuous member), e.g., beam, column or slab edge. Up to 3m
6mm
3m to 6m
9mm
6m to 12m
12mm
Additional for every subsequent 6m 6mm (e) Deviation in squareness shall be measured taking the longer of two adjacent sides as the base line. The shorter side shall not vary in its distance from a perpendicular so that the difference between the greatest and shortest dimensions exceeds 6mm. For this purpose, any error due to lack of straightness shall be ignored. Squareness shall be checked with respect to the straight lines that are most nearly parallel with the features being checked. When the nominal angle is other than 90 degrees, the included angle between check lines shall be varied accordingly. (f) Deviation in twists shall be within a limit such that any corner shall not be more than the limit given below from the plane containing other three corners: Up to 600mm wide and 6m in length 6mm Over 600mm wide and for any length
12mm
(g) Maximum deviation in flatness from a 1.5m straight edge placed in any position on a nominally plain surface shall not exceed 6mm. For Steel Structures: (a) Columns -
SMELTER DIVISION
Deviation of column axes at foundation top level with respect to true axes. i) In longitudinal direction
+5mm
ii) In lateral direction
+5mm
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-
Deviation in the level of bearing surface of columns at foundation top with respect to true level.
+5mm
-
Out of plumb (verticality) of column axis from true vertical axis, as measured at top: i) Up to and including 30m height
+H/1000 or +25mm whichever is less.
ii) Over 30m height
+H/1200 or +35mm whichever is less.
-
Deviation in straightness in longitudinal & transverse planes of column at any point along the height.
+H/1000 or +10mm whichever is less
-
Difference in the erected positions of +5mm adjacent pairs of columns along length or across width of building prior to connecting trusses/beams with respect to true distance.
-
Deviation in any bearing or seating level with respect to true level
+5mm
-
Deviation in difference in bearing levels of a member on adjacent pair of columns both across & along the building
+5mm
Note 1) Tolerance specified for out-of-plumb should be read in conjunction with ‘Deviation in straightness....’ & ‘Difference in the erected positions.’ Note 2) 'H' is the column height in mm. Note 3) Tolerance limits as given under clause (a) above for steel structures are applicable to concrete columns/pedestals also. (b) Trusses - Shift at the centre of span of top chord member with respect to the vertical plane passing through the centre of bottom chord.
SMELTER DIVISION
+1/250 of height of truss in mm at centre of span or +15mm whichever is less
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-
Lateral shift of top chord of truss +1/1500 of span of truss in mm or at the centre of span from the vertical +10 mm whichever is less plane passing through the centre of supports of the truss
-
Lateral shift in location of truss from its true position.
+10mm
-
Lateral shift in location of purlin from true position
+5mm
-
Deviation in difference of bearing of levels of truss from the true level
+1/1200 of span of truss in or 20mm whichever is less.
(c) Gantry girders and Rails -
Shift in the centre line of crane rail with respect to centre line of web of gantry girder + [ web thickness of girder(mm) +2mm] 2
-
Shift of alignment of crane rail (in plan) with respect to true axis of crane rail at any point
-
Deviation in crane track gauge with respect to true gauge: i) For track gauge upto and including 15 m
+ 5 mm
+ 5 mm
ii) For track gauge more than 15m +[5+0.25(S-15)] subject to maximum + 10mm, where S in metres is true gauge. Deviation in the crane rail level at any point from true level
-
Difference in level between crane track rails (across the bay) at
6.1.9
+ 10 mm
-
i) Supports of gantry girders
15 mm.
ii) Mid span of gantry girders
20 mm.
Relative shift of crane rail surfaces (at a joining) in plan and elevation
2 mm
Construction of all other items of works shall conform to relevant Indian Standards and sound engineering practices.
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6.1.10
7.0
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The Contractor shall be responsible for the complete safety pertaining to all construction works. SPECIFIC REQUIREMENTS
7.1
Apart from the conditions mentioned in the Design Requirements given in the document, the following shall be strictly adhered to.
7.1.1
Cable/ pipe trenches & precast slab covers shall be designed to withstand the minimum moving load of a 10 MT hydracrane. Seating surface of the slab shall be at least 100mm wide with structural ISA50x50x6 edge protection embedded through out the length of the trench.
7.1.2
Contractor shall make necessary arrangement for placing the anchor bolts in position before concreting. Whenever there are more than 4 foundation bolts, these shall be fixed by using template. Incase bolts are not available at site at the time of casting of foundation, proper pockets shall be left as per direction of the engineer-in-charge.
7.1.3
The minimum diameter of reinforcement bar for slabs, beam stirrups and column ties shall be 8 mm and for footing slabs and vertical walls it shall be 10 mm. The maximum spacing of these bars shall be restricted to 300 mm c/c.
7.1.4
No equipment shall be directly supported on suspended floor slab. Suitable arrangement of beams shall be provided underneath to support the equipments.
7.1.5
Minimum grade of RCC to be used for civil-structural works shall be M20 as specified. Only steel shuttering shall be used for civil construction. Only minor equipment foundations (weighing up to 1.0 MT) may be considered as lightly loaded structures and founded at shallow depth. The subsoil data and suggestive foundation recommendations are based on soil investigations being carried out at the site. Bidder to carry out confirmatory soil investigations, if required, to check and confirm the soil conditions in the Unit and to develop any additional soil data for foundation design purpose. Contractor shall depute his concerned Civil-Structural design engineer to NALCO's review office as and when required for review of his documents. During such reviews involving computer aided analysis/design/drafting of structures, the Contractor shall make his own arrangement of Personal Computer (PC) in the form of Lap-top in the premises of NALCO's review office. This is required to expeditiously resolve all the comments including those involving the use of PC by Contractor in his submission. The Contractor shall ensure that these PC's are fully operational along with necessary software already loaded including the input/output/drawing files of the structures being reviewed. The Contractor shall revise and re-submit the analysis/design and drawings as required during review.
7.1.6 7.1.7 7.1.8
7.1.9
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Verification of foundation loading data for all euipments/structures/ stacks etc, which form part of the comprehensive packages supplied by the respective vendors, shall be entirely the responsibility of Contractor. Contractor shall ensure that wind/ seismic loadings are strictly in line with the basic wind pressures/site spectra curves enclosed with this bid package.
7.2
PAINTING OF STRUCTURAL STEEL WORKS 7.2.1 For structures surface preparation, Primer & Painting shall be as per relevant clauses of Specification No. 1202-PT-0642-E-05 Rev. 0. 7.3 INTERFACE AT BATTERY LIMIT 7.3.1 Devolopment of proper interface details of structure/structural elements at battery limit is in the scope of the contractor. 8.0 LIST OF ATTACHMENTS A) VENDOR REQUIREMENT – Doc. No. 6593-00-1648-VD-251 Rev. B B) NALCO SPECIFICATIONS/STANDARDS c) SEISMIC DESIGN BASIS – Doc. No. 1202-9-2554-0089 Rev. 0
Serial Standard No. Title No 1 7-68-0417 M.S anchor bolts assembly
Rev No. No. of Sheets 4 7
2 3 4 5 6
4 5 5 3 0
SMELTER DIVISION
7-68-0056 7-68-0501 7-68-0507 7-68-0561 1202-PT-0642E-05
Metal Insert Plates Handrails Steel ladder Standard Grating Details Job specification for shop & field painting
7 10 3 6 17+14
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ENCLOSURE - I FOUNDATION DESIGN - FACTORS OF SAFETY
Type Structure
Tower structure
SMELTER DIVISION
Factor of safety against overturning
Factor Sliding
of
safety
against
With Wind or Seismic
Without Wind or Seismic
With Wind or Seismic
Without Wind or Seismic
1.5
2.0
1.5
1.5
of
%Weight of overburden over projected plan area of footing 50
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ARCHITECTURAL SCOPE OF WORK
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CONTENTS
SMELTER DIVISION
1.0
DETAILED SCOPE OF WORK
2.0
SCOPE OF SUPPLY
3.0
DELIVERABLES BY THE CONTRACTOR
4.0
LIST OF ATTACHMENTS
5.0
ARCHITECTURAL DESIGN BASIS
6.0
SPECIFIC ARCHITECTURAL REQUIREMENTS
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1.0
Detailed Scope of Work
1.1
General Contractor shall develop the FEED to Approved for Construction (AFC) status, taking due account of the detailed requirements of the drawings, design basis, specifications and standards for architectural works for the scope of work covered under this Contract. CONTRACTOR shall not proceed with construction till the documents are reviewed by OWNER /PMC. The scope of architectural works under this contract shall include design, detailed engineering, procurement, supply and construction of all relevant works as per specifications enclosed with the bid document. The scope of work as defined herein shall be read in Conjunction with Architectural Design Basis, Job Specifications for Architectural works and Architectural Standards. Scope of work by the Contractor shall consist of Architectural design & detail engineering including preparation of Architectural drawings, construction including construction supervision & supply of all materials, labour, tools & tackles etc., obtaining approvals from statutory Authorities, supply of deliverables like drawings, documents, preparation of As-built drawings etc and co-ordination with Owner etc. all complete for the following buildings: A)
1.2
MCC ROOM BUILDING RCC framed structure, brick masonry walls, RCC roof.
Detail Engineering Detail Engineering shall be based on "Architectural design basis" and approved preliminary drawings. The Contractor shall prepare construction drawings and submit the same to Owner/PMC for review/approval. The requirement of deliverables by the Contractor for detail engineering is indicated elsewhere.
1.3
Construction The Contractor in strict conformity with Owner/PMC reviewed/approved construction drawings, using materials as per Specifications, Standards & List of Approved Manufacturers as attached in the Tender Documents shall carry out construction including construction supervision. Construction shall include supply of all materials, labours, plants, tools & tackles by the Contractor unless specifically mentioned elsewhere in the Tender Document.
1.4
Statutory Approvals The Contractor shall obtain all necessary approvals from statutory authorities such as Factory Inspector, Tariff Advisory Committee (TAC), Local Municipal or Development Authorities for the design and construction. The Contractor shall also prepare all drawings, documents as required for obtaining such approvals. Any changes/ modifications etc. in design/construction required for obtaining such approvals shall also be done by the Contractor without any time & cost implication to the Owner or PMC.
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2.0
Scope of Supply
2.1
Owner’s Scope of Supply : NIL
2.2
Contractor’s Scope of Supply All architectural materials (consumables/ non-consumables) required for satisfactory completion of the job shall be supplied by the contractor.
3.0
Deliverables by the Contractor
3.1
Drawings / Documents Required with Bid :
3.2
Drawings / Documents Required after Award of contract
NIL
The Contractor shall submit a detailed schedule of submission of deliverables as indicated herewith for review by Owner/PMC as per agreed schedule. Such a schedule shall be made in line with the overall time schedule indicated elsewhere in the Tender Documents. Submission of all deliverables shall be as per the said schedule as reviewed by Owner/PMC. All deliverables shall be prepared using Computer software and shall be complete in all respects including correct titles indicating Owner, Consultant, Contractor, Project name, PMC Job No., Dates, Issues, Revisions and signatures of Performer, Checker & Approver of the Contractor. Incomplete, unsigned & unchecked Documents/ Drawings shall not be accepted and shall be returned. All revisions shall be clearly pointed out clouded for easy identification/ review. All deliverables shall be submitted in requisite number of prints as per methodology mentioned elsewhere in the Tender Documents. Deliverables by the Contractor shall be as listed herewith. 1.
Drawing/Document Schedule and Drawing Index The schedule shall include all Drawings/ Documents with Title, Number, Dates of issues (scheduled & actual) & present review status etc. The schedule shall be updated and submitted at regular intervals as mentioned elsewhere.
2.
Drawings A. Preliminary Architectural Drawings of the buildings in accordance with bid indicating Plans, Sections & Elevations & Architectural treatment. Such preliminary drgs shall be prepared after finalisation of sizes & layout of the required spaces/ areas/ rooms and review of the same by the originating department of PMC.
B. Construction drawings of all the Buildings shall be prepared incorporating comments etc. on the preliminary Drgs. Construction Drawings shall contain the following:
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1. 2.
Plan of all levels, Terrace Plan, Key Plan. Sections as required for complete understanding of the Design & Construction.
3. 4. 5.
Elevations of all sides. Door/Window details. False ceiling details & layouts.
6. 7.
Schedule of Architectural Finishes. Architectural details as required.
8.
Any other drawing as required for complete understanding of the Design & Construction.
Drawings shall be prepared using AutoCAD software of latest (at the time of floating the Tender) version. Drawings shall be prepared in 1:100 or 1:50 scale. For Construction details, Door Window Details the scale shall be 1:20 to 25. For key plans larger but legible scale may be used. 3.
Specifications The Contractor shall prepare & submit specifications of materials etc., which are not covered or attached in the Tender Documents for review by Owner/PMC.
4.
Documents/ Drawings for Statutory Approval The Contractor shall prepare & submit Documents/Drawings for Statutory Approval in accordance with the statutory requirement for Information/Record of Owner/PMC.
5.
As Built Drawings The Contractor shall prepare & submit As-built drawings both in requisite no. of hard prints as well as in form of computer files for Information/Record of Owner/PMC.
6.
List of Sub- vendors/ authorised applicators for specialised items The Contractor shall submit list of all Sub- vendors/ authorised applicators to be engaged for execution of various specialised items (like Aluminium Doors and Windows, Waterproofing and Underdeck Insulation, False ceiling, False Flooring etc.) for approval.
3.3
Review of The Contractor's Drawings/Documents Drawings/ Documents submitted by the Contractor shall be reviewed by Owner/ PMC within agreed upon time schedule. It shall be Owner/ PMC's right to review any/ all or none of the Drawings/ Documents submitted by the Contractor. Review by Owner/ PMC shall not relieve the Contractor of his responsibility for correct Design, Engineering and Construction. The sole responsibility of the correctness of Design, Engineering & Construction shall lie with the Contractor irrespective of the fact that the Drawings/Documents submitted are reviewed or not reviewed by Owner/PMC. The Contractor shall correct all faulty design & construction detected at any stage of work without any cost & time implication to PMC or the Owner. Following Parameters of Design & Drawings shall not be reviewed:
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A.
Adequacy of provisions (in terms of spaces, services & utilities) and space/ area/ Room sizes for Plant Buildings or Plant Areas in other Buildings. The Contractor shall ensure correctness of such provisions visà-vis Owner/ PMC reviewed/ approved G.A. drawings & submit Architectural drgs only after approval/ review of such provisions by concerned deptt. of PMC.
B.
Correctness of Drawings in terms of dimensions, matching of Plan, Elevation, Section, etc. These parameters may be reviewed at random only.
C.
Location, Co-ordinates, Orientation & Road/Ground/Pavement levels. The Contractor shall ensure correctness of these vis-à-vis NALCO’s reviewed/approved G.A. drawings.
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4.0
List of Attachments
4.1
Standard Specifications Sl. no . 01
4.2
4.3
No. of sheet s 08
Specificati on no. 7-49-1101
Title
1
Vendor List for Architectural Products.
Rev.
Title
Standards Sl. no. 01 02 03 04 05 06 07 08
Standard no. 7-75-0011 7-75-0014 7-75-0015 7-75-0027 7-75-0028 7-75-0029 7-75-0031 7-75-0032
No. of sheets 01 01 01 01 01 01 01 01
09
7-75-0043
01
3
10 11 12 13 14 15 16
7-75-0047 7-75-0062 7-75-0063 7-75-0064 7-75-0068 7-75-0070 7-75-0071
01 01 01 01 03 01 01
2 2 2 2 2 2 2
2 2 2 2 2 2 2 2
Wooden flush door with steel frame. Aluminium glazing details. Glazed aluminium window. Steel windows (General Spec.) Steel windows (use of sections) Steel windows (section details) Steel windows (with louvers) Steel windows (fittings & fixtures) Aluminium panel false ceiling (tray type) False flooring details (channel type) European type W.C. fixing detail. Urinal fixing detail. Wash basin fixing detail. Roof drainage & water proofing Pressed steel door (single shutter) Pressed steel door (double shutter)
Job Specifications Sl. no.
Specification no.
01
5.0
Rev.
No. of sheets
Rev.
25
A
Title Architectural Job Specifications
Architectural Design Basis Architectural design of the buildings shall be in conformity with the following:
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5.1
OVERALL PAGE
77 of 455
Codes And Standards A. B. C. D. E.
5.2
PROJECT TITLE
ADDITIONAL LIQUID PITCH HANDLING SYSTEM
National building Code of India Local Municipal or other authority’s bye-laws Relevant state Govt. Factory Acts TAC (Tariff Advisory Committee) regulations Any other rules/regulations/recommendations as applications
Space Requirement: Space requirement shall be based on one or combination of the following depending upon the specific situation a. b. c. d.
Occupancy Equipment layout and clearances Maintenance and safety requirements Storage requirement
The height of the buildings shall be provided as per the statutory requirements and equipments and crane/ monorail requirement. 5.3
Safety Requirements Safety from fire and like emergencies shall be taken into account in building design. Every building meant for human occupancy shall be provided with sufficient no. of exits (as per TAC requirements) to permit safe escape of occupants in case of emergency. Following references shall be adhered to in this regard: A. B. C.
5.4
National Building Code of India State Factory Act Tariff Advisory Committee
Day Lighting And Ventilation Established level of illumination shall be maintained for all parts of the building by means of windows, ventilators, skylights etc. For this IS:3646 Part I & II and IS:2440 shall be adhered to. For the purpose of illumination day lighting shall be supplemented by artificial illumination. Established level of ventilation in terms of air changes per hour shall be maintained for all spaces. IS:3103 and IS:3362 shall be adhered to for this purpose. Natural ventilation shall be supplemented by mechanical/electrical means.
5.5
Aesthetics Architectural design and treatment of the buildings/sheds shall ensure proper aesthetics by adopting general principles of Architecture. An overall architectural control shall be maintained with the rest of the buildings of the project, outside the Contractor’s scope.
5.6
Building Elements a)
SMELTER DIVISION
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All the buildings & sheds shall be provided with minimum 1000 mm wide plinth protection around the building/shed plinth at top of Finished Grade Level. The rain water down pipes shall discharge rain water on this pavement. b)
Steps/ Ramps Steps/ ramps shall be provided for access to the Buildings/ sheds for Pedestrian/Vehicular, equipment entry. Minimum 1000 mm wide platform shall be provided in between Entrance door and steps/ ramps. Following dimensions of the steps/ramps shall be adhered to. A. B. C. D.
c)
Tread = Riser = Slope of Ramp = Ratio of Tread & Riser=
250 mm minimum 175 mm maximum Not steeper than 1:6 2 Riser + Tread= 600 to 648 mm
Windows/ventilators Windows/ventilators shall be provided in all areas for natural lighting, ventilation and visibility at working level. For the purposes of ventilation, total openable area of the windows/ ventilators shall be as per Factory Act subjected to a minimum of 15% of the floor area to be ventilated. However, for Control Room and in office areas etc. where visibility from inside is of prime importance, increased window area shall be provided. Areas accommodating panels/ equipments shall be normally provided with ventilators at high level for unobstructed distributed lighting.
d)
Shading Devices Shading devices shall be provided over all windows, openable ventilators for rain & sun protection. These devices shall be in the form of horizontal projections, vertical projected fins or combination of both as per building facade treatment. Minimum projection shall be 600 mm. Windows in closed condition should not allow any rain water inside.
e)
False Ceiling False ceilings shall be provided for following purposes wherever required. A. B. C.
f)
To reduce room volume and hide ducting etc. for air-conditioned space. To maintain acoustic level inside any space. To reduce habitable room, corridor, lobby, toilet heights located in high ceiling building/ shed to min. 3000 mm.
False/Cavity flooring False/cavity flooring shall be provided to accommodate under floor cabling in Instrumentation Console, Rack, UPS Room etc.
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Specific Architectural Requirements Only relevant clauses as applicable for each type of building shall be referred
6.1
Floor Finishing: function parameters shall
Floor finishing shall be based upon the occupancy or of the particular area. However the following be adopted unless otherwise specified. Panel dividers wherever required shall be provided as per specification.
a.
Equipment handling Area :
50 thk. heavy duty flooring.
b.
Battery Room cement
:
Acid resistant Tiles finish over
conc. flooring. c.
Console/ Rack Room
: False Flooring with high pressure laminate finish.
d.
Office areas, Corridors, : lobby, steps etc.
Kota stone flooring
Toilets
:
e. high dado. f.
6.2
Skirting
:
Ceramic tiles flooring & 2100
125mm high skirting in all areas using same material as that of floor. 1500 high, Acid resistant Tiles finished dado shall be provided in Acid Handling Area.
Doors, Windows, Ventilators Doors, windows, ventilators shall be provided as per requirement. Their sizes shall be according to requirements and equipment to be placed. All doors, windows shall be provided with necessary approved quality fittings and fixtures and painted/polished as per specifications. Doors and windows in air conditioned/ pressurized/ equipment areas shall be airtight and provided with rubber beading all around. Equipment Entry Doors: Pressed Steel doors with 2mm th. sheeting as per requirement. Doors:
Doors in Console Rm., Rack Room and Control Rm. entrance shall be anodized/ powder coated aluminium doors. Doors in toilet shall be laminated wooden flush doors with pressed steel frames.
Windows And Ventilators: Anodized/ Powder coated Aluminium windows & ventilators with 5.5mm thk. toughened glass in Control Room.
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Standard steel windows & ventilators as per IS:1038/ IS:7452 with 4mm thick plain glass in other areas.
6.3
Steel Louvers:
18 gauge M.S. sheet louvers bent to shape as per requirement.
Safety Bars:
12mm square safety bars shall be provided in windows & ventilators as required.
Plastering And Pointing Plastering walls.
:
12mm thick cem. plaster in 1:6 on fair side of all
:
15mm thick cement plaster in 1:6 on rough side of 230 thick brick walls.
:
20mm thick sand face plaster in two coats on all external faces of brick walls.
:
6mm thick plaster in 1:4 in ceiling, chajjas & on
:
15mm thick cement plaster mixed with water proofing compound on inside surfaces of R.C.C. gutter.
:
15mm thick cement plaster mixed with water proofing compound on outer surfaces of the bldg., if required.
:
20 x 10mm groove in plaster as per specifications to be provided wherever required.
cols.
6.4
Roofing Treatment Minimum slope of 1:80 shall be obtained in roof by providing lean concrete 1:3:6 over roof keeping 25mm min. concrete at disposal/ gutter ends. Alternately roof shall be laid to slope as desired. Roof tops shall be given water proofing treatment as specified in Architectural specifications. R.C.C. rain water gutter shall be provided to collect roof water into it. Gutter shall be provided with necessary slopes towards rain water pipes by means of cement screed. 15mm thick water proof cement plaster shall be provided on inner surfaces of gutter and 12mm thick water proof cement plaster shall be provided on outer surfaces of gutter. Any sunk area, before cinder filling shall be finished with 15 mm thk. water proof cement plaster. Rain water downtake pipes shall be C.I. pipes embedded in concrete.
6.5
White Washing, Colour Washing Distempering, Painting, Polishing Ceiling
SMELTER DIVISION
:
All ceiling unless otherwise specified shall be
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finished with three coats of white wash, canopy/ porch ceiling shall be finished with water proof cement. Inside Walls
:
All equipment rooms, instrumentation panel rooms shall be finished with oil bound distemper/ emulsion paint as/ requirement.
Outside Walls
:
All outside surfaces of building shall be finished with water proof cement paint.
Doors And Windows :
6.6
All steel doors, windows & ventilators shall be finished with two coats of synthetic enamel paint over a coat of primer.
Sanitary Fittings/ Fixtures Toilets shall be provided with all necessary approved Indian standard fittings and fixtures.
6.7
False Ceiling and Underdeck Insulation Control Room, Office Rooms, corridors & toilet areas shall have Aluminium plank false ceiling. All air-conditioned areas shall be provided with underdeck insulation.
6.8
False Flooring Control Room shall have false flooring. It shall be provided with lamination top. The height of false flooring from conc. slab or hard floor shall be as per the cabling requirements
SMELTER DIVISION
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ARCHITECTURAL JOB SPECIFICATIONS
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CONTENTS
1.0
1.0
BUILDING REQUIREMENT
2.0
SPECIFICATION OF ARCHITECTURAL FINISHES
BUILDING REQUIREMENT
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The Buildings shall be designed on the basis of basic requirements furnished in these clauses and Design Basis elaborated elsewhere in the bid package. Provisions for LAN (Local Area Networking cabling) shall be considered for the building as per NALCO requirements. Necessary detailing for concealed conduiting through flooring, walls, ceiling/ false-ceiling etc. shall be provided during the detail engineering. In case of conflict or contradictions between building requirement & design basis, provisions of the former shall override. The Buildings shall be sized in accordance with the Owner/ PMC approved GA drawings prepared on the basis of functional, maintenance, safety & statutory requirements as given in the drawings attached with Tender. 2.0
SPECIFICATION OF ARCHITECTURAL FINISHES
2.1
GENERAL (a)
For any aspect of item not covered in the document, the contractor shall follow instructions of the engineer-in-charge and execute the work as per relevant IS codes/ recommendations of approved manufacturer/ good engineering practice without any cost or time implication to Owner/ PMC. Contractor shall refer only to the relevant part of the specifications given below as per the Building Finishes described elsewhere in the bid package.
(b)
All materials shall be of first quality conforming to the specifications & IS or equivalent with IS marks and shall be obtained from the approved Manufacturer. The Contractor shall get the materials approved by the Engineer-In-Charge before ordering & procurement. The Contractor shall furnish necessary certificates etc. as asked by the Engineer-In-Charge. Further to that he shall get the materials tested from approved test house if asked by the Engineers-In-Charge & submit the test certificate at his own cost for which no extra payment shall be made to him. The Engineer-In-Charge shall have the right to reject all or any of the materials intended to be used and such materials shall be immediately removed from the site by the Contractor at his own cost without any claim for compensation etc. due to such rejection.
(c)
Workmanship shall be to the satisfaction of the Engineer- In- Charge. The contractor shall follow the specifications, relevant Codes & Manufacturer's guidelines for achieving desired level of workmanship as per specification & good engineering practice. Any executed work not conforming to the specification or not to the satisfaction of the Engineer-In-Charge shall be rectified by the Contractor as directed by the Engineer-In-Charge. No extra payment shall be made to the Contractor for such rectification. The contractor shall use only first quality approved material for all items.
(d)
All specifications of various finishing items include construction supervision; supply of all materials, labours, tools tackles, scaffoldings etc. and are applicable for all heights, locations etc.
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(e)
For specifications of construction water, sand, cement, bricks/ stone, aggregates etc. reference shall be made to the Civil/ Structural specifications attached in the bid document.
(f)
All specialised items of work (e.g. Aluminium Doors and Windows, Waterproofing, Underdeck Insulation, Precoated roof sheeting/ cladding, False ceiling, False Flooring etc.) shall be got executed by the Contractor only through authorised applicators/ sub contractors of approved manufacturer/ vendor. The contractor shall submit list of such authorised applicators/ sub contractors for approval before execution of such items.
FLOOR FINISHING Reference shall be made to the following Indian Standards for any further information etc. not covered in the specification. In case of any conflict/contradiction, provision of specification shall override. IS: IS: IS: IS: IS:
4971 1237 777 2571 5491
IS: 4441 IS: 4443 (A)
Recommendations for selection of Industrial floor finishes. Specification for Cement concrete flooring tiles. Specification for glazed earthenware wall tiles. Code of practice for laying in situ cement concrete flooring. Code of practice for laying in situ granolithic concrete floor topping. Code of practice for use of silicate type Chemical resistant mortars. Code of practice for use of resin type chemical resistant mortar.
Cement Concrete Flooring Cement concrete flooring shall be laid in average 25mm thickness over sub base (as per structural drawings/ specifications) and shall generally conform to IS: 2571. The flooring shall be laid in panels and shall consist of:
SMELTER DIVISION
(a)
25 mm thick base course of M-15 grade cement concrete (with 6mm and down size stone aggregate) laid on the sub-base in panels (each panel not exceeding 1 Sq. Mtr. in area) in desired shape and pattern. The panels shall be bound by 3x20mm PVC strips panel dividers; fixed in position with their top at proper level maintaining the required levels, slopes, linearity etc. as required. Base course shall be laid in alternate panels. Before laying the base course, neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of area shall be applied (brushed) over the prepared sub base surface. Cement concrete shall be placed in position and beaten with trowel, including tamping and finishing smooth. Finishing of the surface shall follow immediately after completion of laying of base. The bed for flooring shall be prepared either level or sloped as per drawings and as instructed by Engineer-incharge.
(b)
Neat cement @ 2.75Kg. per Sq. Mtr. mixed with water to form a thick slurry applied over the base course (when the concrete is
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green), spread over the surface, pressed twice by means of iron floats; once when the slurry is applied and second time when the cement starts setting. The junction of floor with wall plaster, cladding, skirting shall be rounded off uniformly upto a radius of 25mm unless otherwise mentioned. Each finished portion of floor, on completion shall be kept wet with ponding for a minimum period of 7 days. (B)
Cement Concrete Granolithic Flooring Cement concrete granolithic flooring shall be laid in overall 40mm thickness over sub base (as per structural drawings/ specifications) and shall generally conform to IS: 5491 in workmanship. The flooring shall be laid in panels and shall consist of:(a)
25mm base Course (Under layer) of M-15 grade Concrete (shall generally conform to Civil structural specifications) laid over sub base in panels (each panel not exceeding 1 Sq. M. in area) in desired shape and pattern. The panels shall be bound by 3x30 PVC strips panel dividers; fixed in position with their top at proper level maintaining the required levels, slopes, linearity etc. as required. Base course shall be laid in alternate panels. Before laying the base course, neat cement slurry @ 2.75Kg. of cement per Sq. M. of area shall be applied (brushed) over the prepared sub base surface. The borders of the panels shall have mitred joints at the corners of the room and intermediate joints shall be in straight line with panel joints. Cement concrete shall be placed in position and beaten with trowel and finished smooth. Beating shall cease as soon as surface is found covered with cream of mortar. Necessary slope shall be provided.
(b)
15mm thick Wearing top layer of cement mortar 1:3 (1cement: 3 course sand by volume) which shall be laid within 15 minutes of laying the first layer. The cement and aggregates for the top layer shall be mixed dry. After mixing, sufficient quantity of washed sand and water shall be added to make the mix plastic but not flowing. The top and bottom layer shall firmly grip together. The base course shall be free of excessive moisture before starting the floor finishing. Use of dry cement, cement sand mixture sprinkled on the surface to stiffen the concrete or absorb excessive moisture shall not be permitted.
(c)
While the concrete is still green, cement @ 2.75 kg per Sq.M of floor area shall be mixed with water to form a thick slurry and spread over the surface. It shall be pressed twice by means of iron floats, once when the slurry is applied and second time when the cement starts setting. The junction of floor with wall plaster, cladding, skirting shall be rounded off uniformly upto a radius of 25mm unless otherwise mentioned.
Each finished portion of floor, on completion shall be kept wet with ponding for a minimum period of 7 days.
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(C)
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Heavy Duty Cement Concrete Flooring Heavy duty Cement concrete flooring shall be laid in overall 50mm thickness over sub base (as per structural drawings/ specifications); shall generally conform to IS: 5491 in workmanship. The flooring shall be laid in panels and shall consist of:(a)
Base Course (Under layer) 35mm thick of cement concrete (1 cement: 1.5 coarse sand: 3.5 stone aggregates of 10mm to 6mm size by volume) laid over sub base in panels (each panel not exceeding 1 Sq. Mtr. in area) in desired shape and pattern. The panels shall be bound by 3x40mm PVC strips panel dividers; fixed in position with their top at proper level maintaining the required levels, slopes, linearity etc. as required. Base course shall be laid in alternate panels. Before laying the base course, neat cement slurry @ 2.75Kg. of cement per Sq. Mtr. of area shall be applied (brushed) over the prepared sub base surface. The borders of the panels shall have mitred joints at the corners of the room and intermediate joints shall be in straight line with panel joints. Cement concrete shall be placed in position and beaten with trowel and finished smooth. Beating shall cease as soon as surface is found covered with cream of mortar. Necessary slope shall be provided.
(b)
Wearing Top layer/ Finishing layer shall be of cement, hardener and stone aggregate mix of 15mm thickness laid over the base course. Unless otherwise mentioned, one part of approved quality hardener and four parts of cement by weight shall be mixed dry. This dry mixture shall be mixed with stone grit of 6mm and down size in the ratio of 1 hardener and cement mixture: 2 stone grit by volume. Just enough water shall then be added to the mix.
The mixture so obtained shall then be laid on the base course within 2 to 4 hours of latter's laying. It shall be firmly pressed into bottom concrete so as to have a good bond with it. After the starting of initial setting, the surface shall be finished smooth and true with steel floats. Each finished portion of floor, on completion shall be kept wet with ponding for a minimum period of 7 days. (D)
Cement Plaster Skirting Cement plaster skirting shall be laid with cement mortar (1 cement:3 coarse sand by volume) shall be of 18mm thickness. The surface on which the skirting is to be applied shall be prepared and skirting shall be laid. The junction between flooring and wall shall be rounded off to a radius of 25mm if not otherwise mentioned. While the mortar is still green, cement @ 2.75Kg per square metre shall be mixed with water to form a thick slurry and applied over the mortar. It shall be pressed twice by means of iron floats, once when the slurry is applied and second time when the cement starts setting. The flooring shall be cured for 7 days.
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(E)
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Tile Work (Glazed/ Ceramic/Vitrified Porcelain) Glazed vitreous tiles shall conform to IS: 777. Ceramic tiles for flooring shall be matt finished and non slip type. All tiles shall be decorative type of approved shade, pattern, texture and design and of approved manufacturer. The sizes of the ceramic tiles shall generally be 300x300x8mm for flooring and 100x200x6mm or 300x200x6mm for walls (dado). The sizes of Vitrified Porcelain tiles shall be as per approved manufacturer’s standards/ as approved by owner. Pigments to be admixed with mortar for grouting the joints shall conform to Table -1 of IS: 2114. The tiles shall be laid over a coating of approved neoprene based adhesive (as per manufacturers specification) laid on base floor/ wall plaster. The joints of the tiles shall be flush pointed with cement paste (white cement and pigment conforming to IS:2114, Table-l) matching the shade of colours. The tile work shall be suitably cured.
(F)
Kota Stone Finish Kota Stone Flooring shall be laid in minimum 40mm overall thickness over sub base (as per structural drawings/ specifications). The Kota Stone slabs shall be of selected quality and shade, hard, sound, dense, homogenous in texture, free from cracks, decay, weathering and flakes. These shall be machine cut to the requisite size and thickness and chisel dressed. For flooring and skirting/ dado/ riser the thickness of the stone slabs shall be 25mm and 18mm respectively. Skirting shall normally be 125mm high unless specified otherwise. The slabs shall have smooth top (exposed) face before being laid. Before starting the work, the contractor shall get the samples of slabs approved by Engineer-in-charge. Each slab shall be machine cut to the required size and shape and fine chisel dressed at all edges to full depth and machine rubbed to a smooth surface finish. All angles and edges of the slabs shall be true square and free from chippings giving a plane and smooth surface. Preparation of base shall include making it rough, cleaning thoroughly and applying neat cement slurry @ 2.75 kg of cement per Sq.M. of area to receive the mortar. Cement mortar shall be 15mm thick !:6 (1 cement: 6 Coarse sand by volume) for flooring and 12mm thick 1:3 (1 cement: 6 Coarse sand by volume) for skirting. The mortar shall be laid for fixing one slab at a time. The slab shall be washed clean before laying. It shall be laid over cement mortar bedding on top, pressed, tapped gently to bring it in level. It shall be then lifted and laid aside. Top surface of the mortar then shall be corrected by adding fresh mortar at hollows and depressions. The mortar then shall be allowed to harden and cement slurry of honey like consistency @ 4.4.kg of cement per Sq. M shall be spread over the mortar. The edges of the slabs shall be buttered with white cement (with necessary pigment) grout to match the shade of the slabs. The slabs shall then be gently placed in position and tapped with wooden mallets till it is properly bedded in level. The joints shall be as fine as possible. Surplus cement on the surface of the slab shall be removed. The slabs in flooring shall continue for not less
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than 10 mm under the plaster/skirting. The finished surface shall be true to levels and slopes as instructed by the Engineer-in-Charge. The slabs shall be laid in patterns as per drawings and size shall not be less than 400 x 275mm, which shall be uniform. Cut size may be used along periphery as required. Curing, as required shall be done. Grinding shall be commenced when the joints are properly set. Unevenness at the meeting edges of slabs shall be removed by fine chiselling. Grinding shall be done by machines except for skirting and small areas. First grinding shall be done with Carborundum stones of 48 to 60 grade grit fitted in the machine. Water shall be properly used during grinding. When the floor has been uniformly rubbed, it shall be cleaned with water baring all pinholes. It shall then be covered with a thin coat of cement mixed with pigments to match with colour of the Kota stone. This grout shall be kept moist for a week. Thereafter the second grinding shall be started with Carborundum stone of 120 grade grit. Grinding and curing shall follow again. Final grinding shall be with Carborundum of grade 220 to 350 grit using water in abundance. The floor shall be washed clean with water, oxalic acid powder shall then be dusted at 35 gms/sq. m. on the surface rubbed with machine fitted hessian bobs or rubbed hard with woollen rags. The floor shall then be washed clean and dried with a soft cloth or linen. If any stone slab is disturbed or damaged, it shall be refitted or replaced and properly jointed and polished. (G)
Acid Resistant Tiles Flooring The tiles shall be vitrified ceramic tiles of approved size as per approved manufacturer’s specification and shall be homogeneous having following properties:S.No. Property
Values
Norms
1
Water Absorptions
±0.5%
2
Scratch Resistance
3
Chemical Resistance
Unaffected
ASTM C 650
4
Abrasion Resistance
100
ASTM C 501
5
Breaking strength
1400 kg/ sq.cm
ASTM C 648
6
Density
2.0 Gm/CC
ASTM C 373
6
ASTM C 373
The base course for flooring shall be Cement Concrete flooring/ Cement Concrete granolithic flooring and for skirting/ dado it shall be Cement plaster and background surface shall be prepared as per IS: 4443. Tiles shall be fixed on the prepared surface over a bitumen priming layer, bitumen mastic layer and resin type chemical resistant mortar. The bitumen shall conform to IS: 702 and laying of bitumen mastic shall conform to 1S: 1196.
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Joints shall be allowed to set for 24 hours. The floor shall then be washed as per manufacturer's specifications to totally remove all marks from tile surface. 2.3
DOORS AND WINDOWS (A)
Aluminium Glazed Doors, Windows And Ventilators Aluminium glazed doors/ windows/ ventilators shall be made of extruded tubular Anodised (25 microns)/ Electrostatically powder coated (min. 30 microns) Aluminium sections conforming to IS: 733 and IS: 1285 of `INDAL’ or approved equivalent manufacturer with 5.5mm thk. Toughened glass fixed with rubber lining or EPDM gasket and extruded anodised aluminium beading. Extruded aluminium sections used for various application shall have minimum weights as under. a.
Doors 1.
2. 3. b.
For fixed frames i) Sides & Top members ii) Lock rail iii) Bottom rail For shutter frame Glazing clips (beading)
: : :
1.975 Kg/RM 1.594 Kg/RM : 3.495 Kg/RM 1.202 Kg/RM 0.182 Kg/RM
Window/Ventilator 1. 2. 3. 4. 5.
For fixed frames : For shutter frame : Glazing clips ( beading ) : Coupling bars Member for fixing the frame
0.639 Kg/RM 0.636 Kg/RM 0.165 Kg/RM : 0.933 Kg/RM : 0.463 Kg/RM
The frames shall be fixed to masonry by means of Aluminium lugs fixed to the frame by counter sunk brass machine screws and grouted with M15 grade concrete in minimum 150 x 150 x 50 mm sized hole in the masonry. In case of RCC, the frames shall be fixed with 12mm dia dash fasteners in case of concrete. Any steel item coming in contact with Aluminium shall be galvanised. Aluminium glazed doors shall be provided with cup pivots (of aluminium alloy conforming to IS designation NS-4 of IS 737 and IS designation of A5-M of IS: 617) riveted to outer and inner frames to permit to swing through an angle of 85 degree. Following hardware shall be provided for the doors.
SMELTER DIVISION
1.
Heavy duty & hydraulically operated double or single action adjustable door closer conforming to IS: 6315
2.
250mm and 150mm long, 10mm dia Aluminium tower bolts as per IS: 204 one each for each shutter.
3.
Brass body 6 lever mortise lock as per IS: 2209
4.
Aluminium door handle for each shutter for each side. DOCUMENT TITLE
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(Note: All Aluminium fittings/ fixtures shall be of same finish as that of doorframe & shutter) Side hung window shutters shall be fixed to the frame with Aluminium alloy friction hinges and shall be complete in all respects including accessories, fittings fixtures of same finish as that of window frame & shutter, handles of cast aluminium conforming to IS designation A-5-M of IS : 617 mounted on a handle plate riveted to opening frames, Aluminium Tower bolts, peg stays for ventilators etc. Wherever specified, decorative aluminium safety grills of approved design shall be provided which shall be screwed to the main frame. (B)
Steel Doors Steel doors shall consist of: (a)
Pressed steel door frame of overall 105x 65mm size conforming to IS : 4351 and made of 16 SWG pressed steel sheet bent to required shape using bending machine to form solid/ true mitred edges/ corners, stiffened with 50 x 5mm thick MS flat spacers welded to the frame facing the wall/ column @ 600mm c/c maximum vertical spacing. The frame shall be fixed to the masonry by means of 300 x 25 x 6 mm thick MS hold fast welded to the spacer and grouted with M-15 concrete in minimum 350 x 100 x 100 mm sized hole in the masonry. In case of concrete, the frames shall be fixed by 96mm long, 12 mm dia metallic counter sunk type dash fasteners through the frame & spacers. Provision for hinges, locking arrangement and other hardware shall be provided in the frame by machine cutting of required size cutouts in the frame and welding/ screwing to 3 mm thick MS pad plates already welded over the cutout from behind. The frame shall be thoroughly cleaned of rust, mill scale, dirt, oil etc. and then finished with 2 or more coats of approved quality synthetic enamel paint of approved shade over a priming coat of approved red oxide zinc chromate primer. The hollow frame shall be packed with PCC to fill the cavity without gap.
(b)
Pressed steel door shutter shall be made with 18 gauge steel sheets formed by machine bending in the form of hollow box (overall 40mm thick) welded at meeting of the sheets with pad plate of 3mm thick MS flat all along the perimeter. The shutter shall be braced with channel shaped 35mm wide horizontal stiffeners by folding 16 gauge MS sheets @ 500mm c/c fixed by flush riveting. 3mm thick MS pad plates shall be welded inside at required locations for fixing of hardware. The cavity inside shall be packed with rigid PU foam/ phenolic foam or glass wool insulation to fill into the box cavity without gap. For double shutters, an MS angle (25x 45x 3mm thick) shall be welded to one of the shutter providing a minimum 25mm wide rebate for the other shutter at the meeting point.
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The shutters shall be fixed to the door frame by means of heavy duty MS butt hinges of 150mm size conforming to IS : 1341 @ 500mm c/c maximum. Each door shutter shall have following accessories. 1.
Spring loaded pressure die cast zinc alloy door stopper.
2.
Heavy duty, MS aldrop 400mm long for double shutter & 300mm long for single shutter.
3.
12mm dia, 300mm long pressure die cast zinc alloy handles on both sides.
4.
12mm dia, 250mm long MS tower bolt at top and 12 mm dia 150mm long at bottom.
5.
3- way spring loaded locking & latching system.
6.
150mm x 300mm Vision panel with 16 gauge MS beading bent to ‘Z’ shape & 4mm thick plain glass conforming to IS: 2853.
The entire shutter including all accessories, fittings & fixtures etc. shall be painted with 2 or more coats of approved quality synthetic enamel paint of approved shade over a coat of approved quality red oxide zinc chromate primer. (C)
Wooden Flush Doors Flush doors shall consist of:-
SMELTER DIVISION
(A)
Pressed steel door frame of overall 125x 65mm size conforming to IS : 4351 and made of 16 SWG pressed steel sheet bent to required shape using bending machine to form solid/ true mitred edges/ corners, stiffened with 50 x 5mm thick MS flat spacers welded to the frame facing the wall/column @ 600mm c/c maximum vertical spacing. The frame shall be fixed to the masonry by means of 300 x 25 x 6 mm thick MS hold fast welded to the spacer and grouted with M-15 concrete in minimum 350 x 100 x 100 mm sized hole in the masonry. In case of concrete, the frames shall be fixed by 96mm long, 12 mm dia metallic counter sunk type dash fasteners through the frame & spacers. Provision for hinges, locking arrangement and other hardware shall be provided in the frame by machine cutting of required size cutouts in the frame and welding/ screwing to 3 mm thick MS pad plates already welded over the cutout from behind. The frame shall be thoroughly cleaned of rust, mill scale, dirt, oil etc. and then finished with 2 or more coats of approved quality synthetic enamel paint of approved shade over a priming coat of approved red oxide zinc chromate primer/ approved shade electrostatically powder coated (minimum 30 microns). The hollow frame shall be packed with PCC to fill the cavity without gap.
(b)
Flush door shutters shall be factory made and overall 35mm thick consisting of solid core block board bonded with phenol DOCUMENT TITLE
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formaldehyde synthetic resin conforming to IS : 848. The shutters shall be faced on both sides with 3 mm thick commercial plywood finished with 1 mm thick laminate of approved shade & make. 35 x 20mm second class Teakwood lipping shall be provided all around the shutter by means of approved quality neoprene based adhesive and nailing @ 300mm (maximum). Teakwood lipping shall be french polished (lacquer finish) as per specifications. The shutters shall be fixed to the frame by means of 125mm long MS butt hinges conforming to IS: 1341 @ 600mm c/c maximum. Teakwood used for lipping etc. shall be second class Indian teakwood (conforming to IS : 4021) of good quality, well seasoned and free from defects such as cracks, dead knots, sapwood etc. and shall be with no individual hard & sound knots more than 15 Sq.CM in area and the aggregate area of such knots not exceeding 2% of area of the piece. The wood shall be fairly closed grains having not less than 2 growth rings per Cm. Width in cross section. Following hardware of approved quality and shade shall be provided in each shutter:-
D)
1.
Heavy duty, overhead hydraulically operated door closer conforming to IS: 3564.
2.
Anodised aluminium tower bolts as per IS: 204, 10mm dia 250mm long (at top) and 150mm long (at bottom), one each for each shutter on either side.
3.
Brass body 6 lever mortice lock as per IS: 2209 including pair of handles of pressure die cast zinc alloy (satin finished)
4.
3mm thick plastic kick/ push plate (150mm high at bottom for entire width & 200mm x 100mm at handle location).
5.
Zinc alloy pressure die cast chromium plated spring loaded door stopper with heavy duty rubber shoes.
6.
150mm x 300mm Vision panel with of 4mm thick plain glass conforming to IS: 2853 fixed with second class Teakwood beading (not for toilet doors).
Steel Windows and ventilators Steel windows, ventilators shall in general conform to IS: 1038 and IS: 7452. Rolled steel sections for the fabrication of steel windows, ventilators shall conform to IS: 7452. Glass panels for glazing purpose shall be 4mm thick (wt. 7.2 kg/ Sq.M) The profile and type of windows, ventilators (glazed, partly glazed/ 1ouvred, side hung/ top hung/ fixed shutter, composite) shall be as per approved drawings. The frames shall be constructed of sections cut to size and mitred. Corners shall be welded to form a fused welded joint. Process of
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welding shall be flash butt welding. The welded joints shall be grinded to square and flat edges. Where larger units are to be formed by coupling individual units, the mullions, transoms shall be bedded in mastic to ensure weather tightness. Mastic shall be applied liberally to the channels of the outside frame sections before assembly, and the two units being coupled shall be drawn together tight with clamps, the mastic being squeezed out and cut off neatly when the units shall be screwed together tight. Where fixed glazing units are placed over openable units a push fit weather bar shall be provided. Before glazing, all opening parts shall be checked for their operational smoothness. The frame shall be completely cleaned and bedding putty shall be placed in the rebate before glazing. Glass then shall be cushioned into the bedding and shall be fronted with front putty in a manner so as to enable the painting to be done upto the sight line. The back putty oozing out over the glazing rebate shall be cut off square and smoothed down. For panels exceeding 600 x 300 mm in size, glass shall be secured by special glazing clips inserted in holes already provided in the steel sections, before applying the front putty. For glazing of very large areas, rust proof steel beading with mitred corners shall be provided with screws @ 10 cm. from each corner and @ 20 cm. apart from each other. Putty shall be provided to the face of the bead in contact with glass, in addition to back putty. Side hung shutters shall be connected to the frame by means of friction hinges. The handle for side hung shutters shall be of pressed brass mounted on a steel handle plate welded to the opening shutter frame and shall not be removable easily after glazing. The handle shall have a two point nose, which shall engage with a brass striking plate on the fixed frame in a slightly open as well as in a fixed position. In case of fixing with masonry, holes for fixing the lugs/hold fasts shall be cut at required locations. In case of concrete or stone, the frames shall be fixed by means of dash fasteners. In case of masonry, the lugs shall be grouted in the holes with cement concrete, M-15 Grade when fixing to steel work, mastic shall be applied to the sill of the opening and the unit shall be placed on it with the jambs and head buttered with mastic and the unit shall be fixed with special fixing dips or with nuts and bolts. All the steel surfaces shall be thoroughly cleaned free of rust, mill scale, dirt, oil etc. by sand and shot blasting and then painted with 2 or more coats of approved quality & shade synthetic enamel paint over a coat of approved quality red oxide zinc chromate primer. 12mm M.S. square safety bars (welded to fixed frame horizontally @ 100mm c/c) shall be provided wherever specified. 2.4
PLASTERING
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(A)
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Plain Cement Plaster Plain Cement plaster shall be provided in following thickness: a.
12mm thick in 1:6 cement mortar for all plumbs of the internal masonry walls & RCC Columns coming in line (flush) with this side of wall.
b.
15mm thick in 1:6 cement mortar for rough side of internal masonry walls RCC Columns coming in line (flush) with this side of wall.
c.
The external plastering shall be with waterproof compound (cement mortar mixed with approved acrylic waterproof compound @ 1 Kg. per 50 Kg. of cement) 18mm thick cement plaster in 1:6 cement mortar for all external brick walls and 6mm thick cement plaster in 1:6 cement mortar for all external Rcc surfaces as indicated.
d.
6mm thick in 1:4 cement mortar for all RCC ceiling, beam etc. However if the undulation in ceiling is beyond 6mm thick plaster, extra thickness of plaster shall be applied without any extra cost to give a smooth and fair surface to the satisfaction of EngineerIn-Charge.
e.
Sand face plaster wherever require as per architectural treatment. Sand face plaster shall consist of 13mm thick 1:4 cement mortar (1 cement: 4 coarse sand by volume) under layer and top layer of 7mm thick 1:2 cement mortar (1 cement: 2 coarse sand by volume)
The plastering work shall include preparation of background surface which shall consist of cleaning of all dust, loose mortar droppings, traces of algae, efflorescence or any other foreign matter by water or by brushing, roughening up of smooth surfaces by wire brushing or hacking, trimming of projections whenever necessary. The surface shall be washed off and well wetted before applying the plaster. For external plaster, the plastering shall be started from top floor and carried downwards. Internal plastering shall start with ceiling. Plastering shall be applied evenly in specified thickness. The entire surface shall be finished smooth by means of trowel or wooden float. All the brick masonry and RCC joints shall be provided with 20 gauge chicken wire mesh stretched tight and fixed with G.I. type nails before plastering. 20mm x 10mm grooves (horizontal and vertical) shall be provided in perfect straight line & plumb in plastering as per drawings and instructions of Engineer- In - Charge. Curing shall be started 24 hours after finishing the plaster. The plaster shall be kept wet for a period of 7 days. During this period the plaster shall be suitably protected from all damages at the contractor's expense by such means as approved by the Engineer-in-charge. The date of
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execution of plastering shall be marked on the plastering to ensure the proper duration of curing. The plastering shall include all scaffolding, damage rectification etc. complete. (B)
Sand Face Plaster Sand face plaster shall consist of 13mm thick 1:4 cement mortar ( 1 cement : 4 coarse sand by volume ) underlayer and top layer of 7mm thick 1:2 cement mortar ( 1 cement : 2 coarse sand by volume ) Preparation of background surface, workmanship, curing etc. shall be same as plain cement plaster. The first layer shall be started from top floor and carried downwards. Before the first layer hardens, surface of it shall be roughened up by edges of wooden tapers and close dents shall be made on the surface. The subsequent layer shall be applied over the first layer after the first layer has been allowed to set for 3-5 days depending on weather conditions. The surface shall not be allowed to dry during this period. All the brick/stone masonry and RCC joints shall be provided with 20 gauge chicken wire mesh stretched tight and fixed with G.I. “U” type nails before plastering. 20mm x 10mm grooves (horizontal/ vertical) shall be provided in perfect straight line & plumb in plastering as per drawings and instructions of Engineer- In - Charge. Curing shall be started 24 hours after finishing the plaster. The plaster shall be kept wet for a period of 7 days. During this period the plaster shall be suitably protected from all damages at the contractor's expense by such means as approved by the Engineer-in-charge. The date of execution of plastering shall be marked on the plastering to ensure the proper duration of curing.
The plastering shall include all scaffolding, damage rectification etc. complete. 2.5
ROOF TREATMENT/ WATERPROOF COATING
APP (Atactic polypropylene) modified bitumen Material: The water proofing membrane shall have a non-woven polyester membrane coated on both side with APP (Atactic polypropylene) modified bitumen. It shall have a Black finish with a very thin polyethylene foil on both sides It shall be in rolls of 1x10m for continuous laying on large lengths. When installed, it shall form an impervious, flexible blanket, which accepts normal structural movement without breaking or cracking. Workmanship: a)
SMELTER DIVISION
Preparation of surface:
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The roof surface (or screed) shall be thoroughly cleaned with a wire brush and all foreign matter etc. shall be removed. Well-defined cracks on the surfaces shall be cut to a ‘V’ section, cleaned and filled up flush with a paste of filling compound and cement in the ratio of 1:2. The finished surface shall be perfectly dry and any dampness should be allowed to evaporate. b)
Laying: The membrane shall be laid on the perfectly dry prepared surface by torching-on method with a gas torch. All joints shall have an overlap of 75mm which shall be torch sealed. The overlap shall be done in a manner, which does not hinder water flow along the roof slope. The membrane shall be finished with bituminous base aluminium paint. The waterproofing shall be continued up to the parapet/wall for a minimum of 600mm over the finished roof surface. It shall be continued into rain water pipes by at least 100mm.
c)
Cement Screed: Plain cement concrete (1:2:4) of 25mm min. thickness with 24 SWG chicken wire mesh shall be laid to slope in panels not exceeding 6 m.sq. area per panel over the roof slab. The joints between panels shall be raked out neatly (after stipulated curing period) to a min. 6mm x 6mm V-groove and filled up with an approved quality sealant compound. Drain outlet shall be provided for all spouts/ rain water pipes by suitable rounding, filling and sloping of PCC. At the junction of the roof and parapet or any other vertical surface, a fillet of 75mm radius shall be formed in cement mortar (1 cement: 4 coarse sand).
The finished work shall be measured in M.Sq of area for the purpose of payment. A guarantee of 10 years shall be provided by the manufacturer against the performance of the finished waterproof coating. 2.5.2 Polyurethane (PU) Based Waterproofing The PU based roof treatment/ waterproofing-cum-terracing shall consist of:(A)
The preparation of the surface shall include thorough cleaning of roof surface with a wire brush and removal of all foreign matter etc. Well defined cracks on the surface shall be cut to "V" section, cleaned and filled up with a paste of Polyurethane based crack filling compound and white cement in a ratio of 1:2.
(B) Application of one component urethane prepolymers based elastomeric membrane using Polyether Polyols (Polyester or Castor oil based Polyols are not acceptable) with Iso-cyanurate for rendering flame resistant characteristic.
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The coating shall have physical features like high resistance to impact, abrasion and cracking, superior tensile strength (8 Kg/ Sq.Cm after 4 weeks at ambient temperature) and perfectly smooth, dust free glossy finish retained at least upto 3 years. It should also be resistant to acid, alkalies and have a very low water absorption rate (0.5 % maximum at ambient temperature after 7 days). The one component system shall be in two or more coats of urethane based high solid content elastomeric membrane (having high viscosity to give a high build film) at approx. coverage of 0.5 kg per sq.M each coat. Before the membrane coatings a coat of urethane primer EMP at a coverage of 8 Sq.M per litre by brush shall be applied to achieve overall thickness of 1.5 mm (+ or -15%) as per ASTM C-836/898. Membrane coatings shall be applied after the priming coat is cured to a slightly tacky film (in 2-4 hours) but not later than 48 hours. If delay exceeds this, a fresh coat of urethane primer shall be applied. The second membrane coating shall be applied within 24 hours after the first coating becomes touch dry in 12 to 48 hours (in some conditions this might be delayed) of its application. Subsequent membrane coating, if required shall be applied similarly. Both primer and PU coatings shall be continued to be applied over parapet wall upto 150mm. Each coat shall be allowed to dry for minimum 12 hours before applying next coat. Care shall be taken for quick application after mixing the 2 pack primer in view of short pot life of the mix and shall be fully consumed within the stipulated period as per Manufacturer's specification (maximum 60 minutes at 30 deg.C) The PU coating shall be continued up the parapets/walls for a minimum of 150mm over the finished roof surface. It shall be continued into rain water pipes by at least 100mm. The final coat of PU when tacky shall be sprinkled with 300 micron layer of clean sand. (C)
SMELTER DIVISION
Plain Cement Concrete screed laid to slope of 1:100 ( Steeper slopes shall be adopted for high rain fall regions) in 1:3:6 concrete mix. Minimum thickness of screed shall be 30mm at rain water outlet points. Screed shall be laid only after all the PU coatings are laid and fully cured and checked for the water tightness.
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(D)
Finishing protective layer of 25 mm thk. P.C.C.(1:2:4) in panels of maximum size 1200mm x 1200mm chequered finish with 24 SWG chicken wiremesh interposed in between finished smooth. The joints between panels shall be sealed with suitable urethane based elastomeric compound as per manufacturer’s specifications.
(E)
Fillets of 75 mm radius with P.C.C. (1:2:4) at junctions of horizontal and vertical surfaces shall be provided and finished smooth.
(F)
450mm x 450mm khuras (rain water collecting pits) in 1:2:4 cement concrete at all outlets, levelled down by min. 25mm, finishing, curing etc. all complete.
(Note: The Contractor shall furnish 10 years performance guarantee for waterproofing.) 2.6
WHITE/ COLOUR WASHING, PAINTING, POLISHING ETC. Reference shall be made to the following Indian Standards for further information etc. not covered in the specification. In case of conflict/ contradictions provisions of the specification shall override. IS: 6278:
Code of practice for white washing and colour washing.
IS: 2395: surfaces.
Code of practice for painting concrete, masonry and plaster
IS: 712
:
IS: 55 :
Specification for Ultramarine blue for paints.
IS: 63 :
Specification for whiting for paint and putty.
IS: 5411:
Specification for plastic Emulsion paint for interior use.
IS: 2338:
Code of practice for finishing of wood, and wood based materials.
IS: 5410:
Cement paint, colour as required.
IS: 384
:
Brushes, paints and varnishes, flat.
IS: 486
:
Brushes, sash, tool, for paints and varnishes.
IS: 110:
Ready mixed paint, brushing, grey filler enamels for use over primers
IS: 426
:
Paste filler for colour coats.
IS: 345
:
Wood filler, transparent liquid.
IS: 3585:
Ready mixed paint, alum. brushing priming water resistant for woodwork.
IS: 426
:
Paste filler for colour coats.
IS: 106 on metals.
:
Ready mixed paint, brushing, priming for enamels, for use
SMELTER DIVISION
Specification for building limes.
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All materials required for the execution of painting work shall be obtained direct from approved manufacturers and shall be brought to the site in makers drums, bags etc. with seals unbroken. In case of ready mixed paints, thinning if necessary, the brand of thinner shall be as per recommendations of the manufacturer. Paint shall be applied by brushing or spraying. Spray machine used may be of high pressure type or low pressure depending on the nature and location of work. The paint containers, when not used shall be kept close and free from air. After the finishing of work, the adjacent surfaces not intended to be washed/ distempered/ painted/ polished, shall be thoroughly cleaned of all paint patches and shall be finished in accordance with surface finishing of such surfaces. (A)
White/ Colour Washing White washing in general shall conform to IS: 6278. Scaffolding shall be erected for white washing in such a way that no part of the scaffolding shall rest against the surface to be white/ colour washed. The surface shall be thoroughly cleaned of all dirt, dust, mortar dropping and other foreign matter before white wash is to be applied. Surfaces already white/colour washed shall be broomed down to remove all dust, dirt, loose scales of lime wash or other foreign matters. All damaged portions of the surface plaster shall be removed to full depth of plaster in rectangular patches and plastered again after raking the joints in masonry properly. Such portions shall be wetted and allowed to dry before any operation. All holes, cracks, patches etc. not exceeding 0.1 sq. m. in area shall be made good with material similar to that of the surface. Surfaces affected by efflorescence, moss, fungi, algae, lichen etc. shall be treated in accordance with IS: 2395. The fat lime conforming to IS: 712 shall be slaked at site and shall be mixed and stirred with about 5 litres of water for 1 kg. of unslaked lime to make thin cream. This shall be allowed to stand for a period of 24 hours and then shall be screened through a clean coarse cloth. 4 kg of gum dissolved in hot water shall be added to each cubic metre of lime cream. Approved quality ultramarine blue (for white wash) conforming to IS: 55 @ 3 gram per kg. of lime shall be added to the solution. The whole solution shall be stirred thoroughly before use. For colour washing sufficient quantity of colour wash enough for the complete job shall be prepared in one operation to avoid any difference in colour. Mineral colours of approved shade and quality not affected by lime shall be added to the white wash solution in proportions as directed by Engineer-in-charge. Solid lumps etc. in the colour powder shall be ground to fine powder, sieved and mixed evenly and thoroughly to the white wash solution. White/ colour wash shall be applied with "MOONJ" brush to the in minimum 3 number of coats. The operation for each coat shall consist of stroke of the brush from the top to down wards, another from the down
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to upwards over the first stroke, similarly one stroke horizontally from right and another stroke from the left. Each coat shall be allowed to dry before the next coat is applied. The white washing on ceiling should be done prior to that on walls. Surfaces of doors, windows, floors etc. shall be protected from being splashed upon. Such surfaces shall be cleaned of white/ colour wash splashes. (B)
Oil Bound Distempering The oil bound distempering work shall consist of:(a)
Preparation of surface:The surface shall be thoroughly brushed free from dust, dirt, grease, mortar droppings, other foreign matter and shall be made smooth by sand papering. In case of distempering over existing distempered surface, the existing distempering shall be scrapped by steel scrappers leaving a clean surface. All nails shall be removed. Pitting in plaster shall be made good with plaster of paris mixed with distemper of colour to be used. The surface then shall be rubbed down again with a fine grade sand paper and made smooth. A coat of distemper shall be applied over the patches. The surface shall be allowed to dry thoroughly. The surface affected by moss, fungus, algae, efflorescence shall be treated in accordance with IS: 2395. Any unevenness shall be made good by applying putty made of plaster of paris mixed with water including filling up the undulation and then sand papering the same after it is dry. Scaffolding wherever required shall be erected in such a way that no part of the scaffolding shall rest against the surface to be painted.
(b)
The primer coat:The primer coat shall be alkali resistant primer or distemper primer and shall be of the same manufacture as oil bound distemper.
(c)
Base preparation:After the Primer coat, the base preparation shall include applying two or more coatings of oil based putty in paste form made from chalk powder mixed with linseed oil, white zinc, varnish etc. as per manufacturers recommendations. After each coat of putty, sandpapering of the surfaces shall be done.
Application of Distemper:After the base preparation coats have dried, the surface shall be lightly sand papered and dusted off avoiding rubbing off of the primer coat. The distemper shall conform to IS: 428 and shall be diluted with water or any other prescribed thinner recommended by the manufacturer. Minimum two coats of distemper shall be applied with brushes in
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horizontal strokes followed by immediate vertical strokes, which together shall constitute one coat. The subsequent coats shall be applied after at least 24 hours between consecutive coats to permit proper drying of the preceding coat. The finished surface shall be even and uniform without patches, brush marks drops etc. Application of a coat in each room shall be finished in one operation. 14 cm double bristled distemper brushes shall be used. After each days work brushes shall be thoroughly washed in hot water with soap solution and hung down to dry. Surfaces of doors, windows, floors etc. shall be protected from being splashed upon. Such surfaces shall be cleaned of distemper splashes. (C)
Plastic Emulsion Paint The Plastic Emulsion paint work shall consist of:(a)
Preparation of surface:The surface shall be thoroughly brushed free from dust, dirt, grease, mortar droppings, other foreign matter and shall be made smooth by sand papering. In case of plastic emulsion paintwork over existing distempered/ emulsioned surface, the existing distempering/ emulsion shall be scrapped by steel scrappers leaving a clean surface. All nails shall be removed. Pitting in plaster shall be made good with plaster of paris mixed with plastic emulsion of colour to be used. The surface then shall be rubbed down again with a fine grade sand paper and made smooth. A coat of plastic emulsion shall be applied over the patches. The surface shall be allowed to dry thoroughly. The surface affected by moss, fungus, algae, efflorescence shall be treated in accordance with IS: 2395. Any unevenness shall be made good by applying putty made of plaster of paris mixed with water including filling up the undulation and then sand papering the same after it is dry. Scaffolding wherever required shall be erected in such a way that no part of the scaffolding shall rest against the surface to be painted.
(b)
The primer coat:The primer coat shall be alkali resistant primer or emulsion primer and shall be of the same manufacture as plastic emulsion paint.
(c)
Base preparation:After the Primer coat, the base preparation shall include applying two or more coatings of oil based putty in paste form made from chalk powder mixed with linseed oil, white zinc, varnish etc. as per manufacturers recommendations. After each coat of putty, sandpapering of the surfaces shall be done.
Application of Plastic Emulsion Paint:After the base preparation coats have dried, the surface shall be lightly sand papered and dusted off avoiding rubbing off of the primer coat.
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The plastic emulsion paint shall conform to IS: 5411 (Part- I) and shall be diluted prescribed thinner recommended by the manufacturer. Minimum two coats of plastic emulsion paint shall be applied with brushes in horizontal strokes followed by immediate vertical strokes, which together shall constitute one coat. The subsequent coats shall be applied after at least 24 hours between consecutive coats to permit proper drying of the preceding coat. The finished surface shall be even and uniform without patches, brush marks drops etc. Application of a coat in each room shall be finished in one operation. 14 cm double bristled distemper brushes shall be used. After each days work brushes shall be thoroughly washed in hot water with soap solution and hung down to dry. Surfaces of doors, windows, floors etc. shall be protected from being splashed upon. Such surfaces shall be cleaned of splashes. (D)
Plaster of Paris Punning Plaster of Paris punning shall be applied over roughened plastered surfaces. Superior quality Plaster of Paris of approved make shall be mixed with water to obtain paste like consistency and shall be applied on walls, ceiling etc. in sufficient thickness to give an absolutely smooth, plumb and straight surfaces.
(E)
Waterproof Cement Paint Scaffolding shall be erected for white washing. The surface shall be thoroughly cleaned of all dirt, dust, mortar dropping and other foreign matter before white wash is to be applied. Surfaces already white/colour washed shall be broomed down to remove all dust, dirt, loose scales of lime wash or other foreign matters. Scaffolding, Preparation of Surface shall be same as white wash. The surface so prepared shall be thoroughly wetted with clean water before the paint is applied. Waterproof cement paint of approved make shall be mixed with water and stirred to obtain a thick paste, which shall then be diluted to brushable consistency. The proportion of mixture shall be as per manufacturer's recommendation. The paint shall be mixed in such quantity, which can be used up within an hour of mixing to avoid setting and thickening of the paint. The surface shall be treated with minimum two coats of waterproof cement paint. No less than 24 hours shall be allowed between two coats and subsequent coats shall be applied only after the preceding coat has become hard to resist marking by subsequent brushing. The finished surface shall be even and uniform in shade without patches, brush marks, paint drops etc. Cement paints shall be applied with a brush with relatively short stiff hog or fibre bristles. Curing shall be started after the paint has hardened. Curing shall be done by sprinkling with water two or three times a day. This shall be done between coats and for at least two days following the final coat.
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(F)
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Painting of Steel and Other Metal Surface Reference shall be made to IS: 2524 and IS: 1447. The surface, before painting, shall be cleaned of all rust, scale, dirt and other foreign matter with wire brushes, steel wool, scrappers, sand paper etc. The surface shall then be wiped finally with mineral turpentine, which shall then be removed of grease etc. The surface then shall be allowed to dry. In case of GI surface, surface so prepared shall be treated with Mordant solution (5 litre for about 100 sq.m.) by rubbing the solution generously with brush. After about half an hour, the surface if required shall be retouched and washed down thoroughly with clean cold water and allowed to dry. Approved quality primer and paint in specified numbers of coats shall be applied as per manufacturer's recommendations either by brushing or spraying. Each subsequent coat shall be applied only after the preceding coat has dried.
(G)
Painting Of Wood Surfaces (Synthetic Enamel Paint) Preparation of wood surface shall conform to IS: 2338 (Part-1) in general. All woodwork shall be dry and free from any foreign matter. Nails shall be punched well below the surface. The surface shall be smoothened off with abrasive paper used across the grain prior to painting, with the grain prior to the staining. Any knots, resinous, or bluish sapwood, cutting out of which is not justified shall be covered with red lead conforming to IS: 103. Painting of wood surfaces shall consist of:(A)
Priming Priming shall be in accordance with IS :2338 (Part I and II). Dirt or any other extraneous material on the surface shall be removed and the priming shall be applied by brushing. Priming shall be done on all exposed and unexposed surfaces. Unless specified otherwise all joinery work intended to be painted shall receive at least 2 coats of primer. Type of primer shall be in accordance with Table-1 and Table-2 of IS: 2338 (Part-II).
(B)
Stopping and Filling Stopping and filling shall be done after priming. Stopping shall be made to the consistency of stiff paste and shall be used to fill holes and cracks. Filler shall be used to level up slight irregularities of the surface. Filler shall be applied with a putty knife and subsequently rubbed down to a level surface with
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abrasive paper. The filler coat shall be allowed to fully flatten and harden before subsequent coat is applied. (C)
Application of Undercoat Under coat shall be applied after the surface has been primed, stopped and filled, and rubbed down to a smooth surface. Under coat may be brushed or sprayed. After drying the coat shall be carefully rubbed down and wiped clean before the next coat is applied. The type of undercoat shall be depending upon the finishing and in accordance with Table 1 and Table-2 of IS: 2338 (Part II).
(D)
Finishing The finishing paint shall be two or more coats of synthetic enamel paint and shall be applied either by the brush or by spraying to give a uniform, smooth and glossy finish.
Reference shall be made to the Table-1 and Table-2 of IS: 2338 (Part-II)
2.7
ROOFING Reference shall be made to the following Indian Standards for information etc. not covered in the specification. In case of any conflict/contradiction, provisions of specification shall override. IS 1728
:
Specification for sheet metal rain water pipes upto 100 mm nom. size gutters, fittings and accessories.
The roof slope shall be as specified and in general not pitched flatter then 1:5. The normal pitch if not specified shall be 1:2. Materials shall be supplied by approved manufacturer. The items supplied shall be free from cracks, chipped edges or corners or other damages. Storage and safety precautions shall be taken to avoid damage to the accessories. 2.7.1 C.I. Rain Water Pipes C.I. rain water pipes shall be 100mm dia or 150mm dia (as specified/ indicated in drawings); shall conform to I.S:1729. The pipes shall be provided complete with necessary clamps, connections, bends, Tees, other accessories (as per approved manufacturer’s specifications) and shall be jointed with spurn yarn and cement mortar 1:2 (1 cement: 2 fine sand by volume). Embedded rain water pipes shall be suitably embedded/ encased in masonry/ cement concrete (M-15) with nominal reinforcement.
2.8
SANITARY FITTINGS AND FIXTURES Reference shall be made to the following Indian Standards for any further information etc. not covered in the specification. In case of any conflict/ contradiction provisions of specification shall override.
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IS-2556: Part 1-
Specification for Vitreous Sanitary appliances (Vitreous-China, 15).
1S-774 :
Specification for Flushing Cistern for Water Closets and Urinals.
IS-781 :
Specification for Cast copper alloy screw down bib taps and stop valves for water services.
IS-2064:
Code of Practice for Selection, Installation and Maintenance of Sanitary appliances.
All glazed earthen ware shall be of approved make, colour and of one piece construction. All metallic fixtures like taps, stop cocks, soap holders etc. shall be CP brass and approved make. All wall fittings shall be fixed with nylon sleeve and CP brass screws and washers. (A) Indian Type Water Closet Squatting Pan shall be 550mm x 440mm Orissa Pan conforming to IS: 2556 Part-III with integrated footrests. The closet shall be fixed in the floor with 150 mm thick sand cushion and shall be connected with 100 mm dia CI `S' or `P' trap. The closet shall also be fitted with 10 litres valve less syphonic type glazed earthenware flushing cistern, conforming to IS: 774, and complete with all accessories like 15 mm dia. PVC inlet connection pipe 450mm long (with 15mm dia CP Brass stop cock and brass union), PVC ball valves, C.P Brass handle, telescopic 32 mm dia GI telescopic flushing pipe with union, 15 mm dia GI overflow pipe with mosquito proof net and fixed with glazed earthenware cover. The cistern shall be fixed on MS brackets at a minimum height of 2150 mm from top of pan. All exposed metallic surface shall be painted with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer (primer is not required for GI pipes). One number heavy grade approved quality CP Brass bib cock conforming to IS: 781 (with necessary connections) shall be provided with each WC. The work shall include providing and fixing water-closet and flushing cistern with all accessories, breaking wall and floors and making good the same, all inlet and outlet connections of cistern and water closet, finishing of solder joints, painting and testing of all connections etc. complete. (B) Wash Down (European) Type Water Closet Wash down water closet shall be of pattern-1 conforming to IS: 2556 Part-II. Water Closet shall be of one-piece construction, double trap syphonic type. This shall be fixed with plastic seat and cover as per IS: 2548 of approved make and colour, fixed with CP brass hinges and rubber buffers and an integral 100 mm dia 'S' or 'P' trap with antisyphonage vent horn. A low level earthenware cistern conforming to IS: 774 of about 10 litres capacity, with 15mm dia PVC inlet pipe (with 15mm dia CP Brass stop cock) and brass union with wiped solder joint, internal overflow arrangement, 40 mm dia CP brass flushing pipe. CI or MS supporting brackets shall be fixed with the water closet. The closet shall be fixed firmly in the floor with matching cement mortar. All exposed metallic surfaces shall be painted with two coats
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of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer. The clearance between top of pan and bottom of cistern shall not exceed 300 mm. One number heavy grade approved quality CP Brass bib cock conforming to IS: 781 (with necessary connections); one number approved quality CP Brass Toilet paper holder (fixed to wall with wooden cleats, CP Brass screws) shall be provided with each WC. The work shall include providing and fixing of all fittings, breaking floors and wall, making good the same, making inlet and outlet connection to the cistern and the closet, testing of joints, painting the exposed metallic surface with two coats of synthetic enamel paint over a coat of primer etc. complete. (C)
Urinals Half stall type urinal shall be of size 610mm x 400mm x 380mm and conforming to IS: 2556 Part VI. Urinals shall be of single piece construction with integral flushing box rim. These shall be mounted on walls. The flushing inlet pipe shall be of CP brass 15 mm dia and waste pipe 32 mm dia GI, 750 mm long shall be embedded in wall. Necessary unions and CP bottle trap shall be provided in the waste line. Rawl plugs with CP brass screws shall be used for fixing the urinal. Fixing shall ensure that no liquid is left over in the pan after flushing. Unless otherwise indicated height above finished floors shall be 600 mm. Urinals shall be connected to glazed earthenware automatic flushing glazed earthenware cisterns either individually, or in groups. Where individually connected to flushing cistern, the cistern capacity shall be 5 litres. For two urinals, one cistern of 10 litres capacity and for three urinals, one cistern of 15 litres, capacity shall be provided. Cistern inlet shall be 15 mm dia PVC pipe with brass union. Outlet pipe from cistern shall be 25mm CP brass main, with 15 mm CP distributor pipe of sufficient lengths to reach each bowl. Where individual cisterns are provided the outlet shall be of 15 mm CP brass. The work shall include urinals inlet and outlet pipes, flushing cistern, breaking and making good the walls and flooring, making inlet and outlet connections including all related G.I. piping work (embedded in wall), painting exposed brackets and exposed metallic parts with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer etc. all complete. All The Urinals shall be separated by Marble partitions (of minimum 19mm thick White Makrana marble slabs; each partition in one piece) of minimum size 1000mm x 600mm. These partitions shall be inserted upto 100mm depth in the wall and fixed with cement mortar 1:3 (1 cement: 3 coarse sand by volume) and suitable sized M.S. Channel (embedded in wall with grouting) at bottom. The M.S. Channel at bottom shall be finished with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer. (D)
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Wash Basins
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This shall be flat back wash basin (with require number of tap holes and conforming to IS: 2556 Part-IV) with anti splash rims on three sides, of size 550mm x 400mm size. Wash basins shall be of one piece construction including a combined overflow having an area of not less than 5 Sq. cm. shall be provided in the front or back of the bowl and it shall be so designed as to facilitate cleaning of the overflow. This shall be fitted on CI or MS brackets. Brackets shall conform to IS: 775. The brackets shall be given two coats of synthetic enamel paint or aluminium paint, over a coat of approved primer. Each wash basin shall be provided with 15mm dia CP brass pillar cock of approved make, rubber plug with CP brass chain, 32mm CP Waste fitting of standard pattern with 32mm dia G.I. pipe, CP Brass bottle trap, CP Brass 15mm dia stop cock etc. complete with all related accessories, fittings and fixtures. The wall side shall be fixed well flushed with the plaster or wall and the joint if any, shall be properly stopped with an elastomeric sealant. The top of rim of the wash basin shall be fixed at 800 mm above finished floor level, unless otherwise specified. The work shall include provision and fixing of wash basin with all accessories, providing stop cocks and pillar cocks, breaking and making good walls, fixing and making inlet and outlet connections for stop cock, pillar cock and waste pipe, providing & fixing MS brackets painted with two coats of synthetic enamel paint of approved quality over a coat of red oxide zinc chromate primer etc. complete. Following fixtures of approved quality shall be provided for each Wash Basin. 1.
Mirror
:
Round edged Mirror of 5.5mm thick (minimum size of 400mm x 550mm) plain glass with 6mm thick AC sheet backing, beveled edged.
2.
Glass Shelf
:
600mm x 120mm x 4mm thick Glass shelf with CP brass bracket & guard rails ; fixed on wall.
3.
Towel Rail
:
4.
Chromium plated brass towel rail of 20mm dia 600mm length & 1.25mm thickness. Liquid soap container:Chromium plated Liquid soap container.
All the fixtures shall be fixed to the wall at identified locations with wooden cleats and CP Brass screws including cutting walls, making good the same etc. complete.
2.9
FALSE CEILING, FALSE FLOORING, UNDERDECK INSULATION ETC.
2.9.1
Aluminium Lineal False Ceiling Aluminium lineal false ceiling shall consist of:(A) Panel Carriers:-
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These shall be roll- formed out of coated steel/ 0.95mm thick aluminium alloy; 32mm wide and 39mm deep with cut-outs to hold panels in a module of 90mm/ 100mm; all complete as per manufacturer’s standard details and specifications. When two or more carriers are to be joined, they shall be joined together by means of carrier splices which will clip on to holes in the sides of the carriers and hold them firmly in place while maintaining the required module. The carriers shall be suspended from roof by 4mm dia. galvanised steel wire rod hangers, with height adjustment springs of stainless steel. Hangers shall be fixed to roof by “J” hooks and nylon inserts. Edge profiles shall be “L” shaped roll- formed out of 0.6mm aluminium alloy with coating. (B) Panels:Panels shall be 84mm wide, 16mm deep, roll formed out of 0.5mm aluminium alloy 5050 or 3005. The aluminium panels shall be chromatised and stove enamelled (coil coated) on both sides in approved shade. Panels shall be factory cut in lengths upto 5 metres to suit site dimensions. As per airconditioning requirements, for return air, (wherever required) perforated panels shall be used, which shall have 2mm dia holes at 5mm centre to centre staggered in uniform pattern and symmetrically located in the middle of the panel face. The ceiling shall be erected in continuous manner as per approved manufacturer’s recommendations, specifications etc. The false ceiling shall have perfect levels, linearity etc. as required. Necessary cut outs for Electrical, AC and other fixtures shall be provided as per drawing and in co- ordination with relevant construction activities.
2.9.2 Aluminium Planks/ Tiles False Ceiling This false ceiling system shall consist of:(a)Panel carriers:These shall be rows of 0.5mm thick galvanized steel clip in profiles of size 40mm x 20mm. These shall be suspended from roof structure by means of G.I. suspension angles, ceiling brackets and hold on clamps @ maximum 1200mm c/c all complete as per approved manufacturer’s specifications. (b)Aluminium Tiles:Aluminium Ceiling Tiles shall be 600mm x 600mm manufactured out of 0.7mm thick aluminium alloy AA3105, chromatised and stove enamelled (coil coated) with square edges produced on advanced equipments. Exposed side of the tile shall have 20 micron (minimum) coil coated polyester finish and 5 micron back coat of Alkyd primer. The short sides of each plank shall be raised and pipped and stopped to ensure positive engagement into the spring clip- in profiles, and shall allow for demounting of individual planks. (B)
Underdeck Insulation Phenolic Foam Underdeck Insulation:-
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Phenolic Foam Underdeck insulation shall be of rigid slab of 25mm thickness and approx. 1000mm x 500mm size as specified and shall conform to IS: 13204. It shall have density of 32 kg / M3 and K Value 0.016 KCal/hr M C as per BS 4370, Part 2. The insulation shall be classified as `Non Combustible' as per BS 476, part 5 and ‘Class I’ for surface spread of flame as per BS 476 ,part 7. It shall be prelaminated on both sides with kraft paper. The entire soffit of slab and beams shall be thoroughly cleaned. Bituminous primer or zinc chromate primer shall be applied evenly @ 0.5 kg/m2 over the entire surface. Hot bitumen or CPRX adhesive shall then be applied on the insulation panel @ 1.5 kg/Sq.M. The panels shall be pressed in position and further secured by dash fasteners. The underdeck insulation shall be fixed only after all fixtures like hooks, clamps, cleats etc. for light fixtures; ducts etc. have been fixed in the ceiling. 2.10 MISCLLENEOUS ITEMS (A)
Plinth Protection (Without Drain) The plinth protection (all round the buildings- without drain) shall consist of a layer (150mm thick) of compacted sand and over that 100mm thick M-15 grade concrete top layer laid to slope. The top concrete layer shall be trowel finished, cured etc. complete. The work also includes carrying out the necessary excavation, disposal of surplus earthwork etc.
(B)
Cinder Filling All the sunk R.C.C slabs shall be provided with cinder filling comprising
of:-
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(a)
Plastering the R.C.C. slab top, sides etc. with 18mm thick cement plaster 1:6 (1 cement: 6 sand by volume) mixed with approved waterproof compound @3% of cement by weight and finishing with a floating coat of neat cement slurry @ 2.75 kg. per sq. Mtr, finishing, curing etc. The work includes preparation of base surface as described in Plastering item.
(b)
Filling with Cinder concrete 1:10 (1 cement : 10 cinder of 12mm and down grade) including consolidating, finishing, curing etc. complete.
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CIVIL - STRUCTURAL VENDOR REQUIREMENTS
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Vendor Data Requirement (Structural) Sr.No .
Description
With Bids For For Review Inform ation/ Record s *
1.
Design Basis
2.
Support structure for silo
*
3.
Support structure for equipments
*
4.
MCC & Control room
*
5.
Other structures etc.
6.
Deviation schedule w.r.t.
7.
8. 9.
Remark s
*
a. Specification
*
b. Document/attachments
*
Undertaking that there is no other deviation other than specifically mentioned in deviation schedule. Undertaking for covering full scope of MR List of drawings/documents with submission schedule.
*
* *
Notes:
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1.
Unless otherwise agreed, the number of copies of various drawings and documents shall be as indicated elsewhere in the bid document.
2.
Vendor shall furnish Schedule of Vendor drawings and documents within 15 days after placement of FOI/LOI.
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STANDARD SPECIFICATION FOR ELECTRICAL SYSTEMS
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ELECTRICAL SPECIFICATION & MCC ROOM
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01. INTRODUCTION This specifications defines the scope of work and minimum basic requirement for electrical system design, engineering, equipment selection, sizing procurement, supply erection, testing and commissioning for Additional Storage Tank for Liquid Pitch Handling Complete in all respect for M/s Nalco’s, Smelter Division, Green Anode Plant (GAP) at Angul, Orissa. The intent of this requisition is to outline the requirement of additional storage and handling facility for liquid pitch of Green Anode Plant(GAP), Smelter Division, M/s National Aluminium Company Limited, Angul, Orissa, which include Site Assessment of existing Storage Tank for Liquid Pitch Handling system to have preliminary idea, Estimation of the Works, Design, Engineering, Procurement, Fabrication, Assembly, Supply of electrical portion, Shipment, Inland Transportation, Receipt at site, Storage, Erection, Installation, Painting, Hookup with existing automation system of GAP, Testing and Commissioning of the complete proposed system in accordance with the specifications enclosed with this document. In the process of engineering, vendor may have to assess the site for gauging physical requirements of the existing electrical and instrumentation works/supplies and collect data relevant to the process design. The necessities to have an additional storage and handling facilities of liquid pitch complete has become inevitable as a result of increase and sustained Anodes requirement in Potline for smelting process. We intend to design, supply, erect, install, test, commission and handover the complete system through capable turnkey contractor/ vendor who have prior experience of handling similar works. The following shall be the tentative scope of work, Study of the existing system to gather preliminary idea, site assessment for Electrical Works/Supplies, Study of P & I Diagram, Process Flow Diagram, Schemes and Layout. Estimation of Electrical Works/Supplies. Procurement of MCC of IP 54 Enclosure, Bus Ducts, UPS, Pump Motors and other electrical and instrumentation accessories etc. Basic engineering, detailed engineering for electrical work and supply based on existing site conditions. Manufacturing, supply, construction, erection, testing & commissioning and performance guarantee of the whole Additional Storage Tank for Liquid Pitch Handling similar to or upgraded version of existing system. After sales technical assistance, maintenance spares support, service supports and technological up gradation of the Additional Storage Tank for Liquid Pitch Handling in future.
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Construction of a MCC Room to install the supplied M.V.Switch Board (MCC) and other electrical and instrumentation auxiliaries suitable only for indoor application. The system shall be ‘One Complete Operating Unit’ including all required auxiliary equipment for efficient and satisfactory operation as a whole. Vendor shall be responsible for furnishing all electrical, instrumentation and other inter-connecting and safety items as required to make the system complete. Vendor shall have to give Performance Guarantee of the Complete Additional Storage Tank for Liquid Pitch Handling and ensure after sale Technical Assistance, Maintenance Spares Part Support, Service Support and Technological up gradation as and when required due obsolescence of major or minor components of the proposed liquid pitch storage and handling system. All equipment and materials supplied and installed under these specifications and drawings shall be installed in accordance with sound engineering principles and good fabrication and construction practices. No omission from these specifications shall relieve the vendor of his responsibility for an adequate system as above. All materials supplied under this requisition shall be adequate for proposed service. Proper consideration shall be given to their function with regard to corrosion, chemical and process hazards and erosion due to the material being handled. 02. BRIEF DESCRIPTION OF ELECTRICAL SYSTEM All 415V motors of any ratings including Main Feeding Pump Motor, Discharge Pump Motor and its auxiliary like stirrer etc, of Additional Storage Tank for Liquid Pitch Handling system complete, shall be fed from 415V AC MCC of IP 54 Enclosure which shall be located/ installed near GAP MCC of Sub-Station No. 16. For catering to all 415 V AC loads of Additional Storage Tank for Liquid Pitch Handling, required 415V AC (MCC) switchboard of IP 54 Enclosure shall be in Vendor’s scope. This (MCC) switchboard shall be located in a MCC Room near the Sub-Station No.16. This vendor’s (MCC) switchboard shall also receive power from Owner’s 415 V AC main switchboards located in the Sub-Station no.16. Lighting loads shall be fed from lighting panels which in turn shall be fed from lighting distribution board located in the above sub-station. Owner will not provide required number of 415V, TPN, 50Hz starter feeders for all motors for the proposed Additional Storage Tank for Liquid Pitch Handling. One number 415V TPN, 50Hz feeder or ACB, depends on requirement, shall be provided for the 415V AC (MCC) switchboard of vendor’s scope, as mentioned above. Further distribution and any other voltage required shall be derived by the vendor. This (MCC) switchboard shall house all starters and switch fuse feeders for MV motors and other loads for the system/package of Additional Storage Tank for Liquid Pitch Handling. All interlocking for the desired sequence of operation, selections, indications, integration with existing Green Anode Plant for automation shall be carried out by the vendor only.
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Supply of all power and control cables for the electrical loads of the system being fed from vendors 415V Main (MCC) switchboard, their installation, termination at both ends, testing and commissioning of the same shall also be in vendor’s scope. The incoming cable to vendor’s 415V AC (MCC) switchboard mentioned above from Owner’s Sub-Station-16 shall also be supplied by the Vendor and their installation, termination at both ends, testing and commissioning of the same shall be in vendor’s scope. Liquid Pitch temperature & rater of flow to the GAP, may vary from time to time, each and every day, during plant operation depends on process requirement of Green Anode Plant. Hence vendor shall, if required for improved technical reasons, provide the Main Circulating Pump Motor in line with Variable Frequency Drive (VFD) instead of DOL. The Speed of the Pump Motor shall be varied through 4-20 mA analog Input and Output from Flow Meter, Temperature Sensor and VFD. This design should help in smooth Starts/Stop of Main Circulating Pump Motor of proposed Additional Storage Tank for Liquid Pitch Handling system, negligible damage to Mechanical Equipments, Civil Structure in addition to less usage of KW and enormous amount of electrical energy saving. Addition of Variable Frequency Drive should also eliminate the use of expensive Vane Actuator Motor and Damper for flow control. Owner will not provide an M.V.Switch Board Room or MCC Room for placement and installation of all indoor electrical and instrumentation equipments including supplied MCC as stated above. Owner will provide only space earmarked for complete Additional Storage Tank for Liquid Pitch Handling project of GAP. Vendor has to build or construct the required MCC Room to install all supplied or required electrical and instrumentation equipments suitable for only indoor applications within the earmarked place. The construction and illumination of this MCC Room shall be in vendor’s scope of work. The MCC Room shall be with false flooring so as to have required cable trays underneath. All the incoming and outgoing cables from M.V.Switch Board (MCC) to the motors and field equipments complete for Additional Storage Tank for Liquid Pitch Handling shall be routed through these cable trays. The MCC Room shall be constructed or build considering all aesthetics, safety, environment, ISO Standards, electrical statutory regulation laid by local body, state and central government from time to time. The atmosphere in the vicinity of GAP may have conductive carbon and Coal Tar Pitch dust. The MCC Room shall have double door arrangement to avoid ingression of these dusts and above factors shall be considered while designing the electrical & instrumentation installation/equipments/building. Nalco have cable tray network for its power and control cables of GAP. However additional cable trays, if required, for the proposed Additional Storage Tank for Liquid Pitch Handling system shall be provided and installed by the vendors. The cable tray shall be as per the standard specifications of Nalco and shall be purchased from approved vendor list of Nalco. In case some portion of electrical equipment is not available in the approved vendor list then prior approval shall be taken from Nalco before supply or manufacturing.
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The proposed Additional Storage Tank for Liquid Pitch Handling system complete shall be similar to or technically upgraded system of existing Additional Storage Tank for Liquid Pitch Handling system of GAP-2. In a nut shell, a system may be considered, which shall be minimum a replica of existing system of GAP-2, with latest technical aggradations. General illumination for main roads access roads the GAP/Building and general illumination requirement inside the GAP/building shall be provided by Owner. However, all lighting specific to the system such as near pump, above storage tank and other areas such as stairs, etc. and illumination within the Additional Storage Tank for Liquid Pitch Handling Area’s shall be in vendor’s scope. 3. SCOPE OF WORK 3.1
Vendor’s scope includes detail engineering, equipment sizing, selection, procurement, supply, and erection, testing, commissioning and handing over to M/s NALCO the complete electrical system of Additional Storage Tank for Liquid Pitch Handling system complete.
3.2
System Design and Detail Engineering : Vendor shall perform the design and detail engineering activities including but not limited to following: •
Preparation of electrical load data and its analysis,
•
Preparation of Single line diagram,
•
Preparation of control, power and protection schematics,
•
Lighting system design calculations,
•
Preparation of cabling, lighting, earthing and protection layout drawings including associated documents such as cable schedule, lighting/power panel schedules, etc.
•
Preparation of interconnection diagrams and integration diagram with existing Green Anode Plant,
•
Preparation of Bill of Material for cabling, lighting, earthing and lighting protection system and miscellaneous items,
•
Preparation of electrical equipments list and motor list,
•
Preparation of as built drawings,
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•
3.3
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Preparation of automation scheme of Additional Storage Tank for Liquid Pitch Handling system and hooking with existing automation system of GAP.
Supply of Equipments/Material: Vendor shall supply all equipments/material required for completeness of the offered system, including but not be limited to following: •
415V switchboards of IP54 enclosurefor feeding all MV/LV loads,
•
Local Power Isolation or Load Break Switch (LBS) cabinet with load switch for each 415V motor,
•
All HV, MV and LV motors.
•
Local Control Stations for local operation of motors with Start/Stop Push Buttons, Ammeters (for all motors). It shall also contain other devices like selector switches, as per operational requirements.
•
Complete Variable Frequency Drive (VFD) Panels with Power Isolator, Power Fuses, Power Contactor, Input and Output Choke, Control Transformer, required Terminal Blocks, Panel Illuminations and Exhaust Fan for cooling in Rittal Make IP65 Enclosure only. The Specification of VFD shall be as per Nalco’s Standard Specifications of VFD.
•
Emergency Stop Push Button Cabinets distributed throughout the work area,
•
Lighting/Power panels,
•
Lighting fixtures, lamps junction boxes, 5A/15A receptacles, accessories and associated wiring,
•
240V AC, 1-Phase UPS system of minimum 5k VA rating, required for PLC/ instrumentation loads,
•
All MV Power and Control cables required for interconnecting equipment supplied by the vendor,
•
All special cables (if required) for interconnecting equipment supplied by the vendor and for interconnecting vendor’s equipment to purchaser’s equipment or existing Green Anode Plant.
•
Cable trays, supporting racks, risers , duct, GI pipe sleeves and accessories like cable glands, lugs, markers, tags etc. required for the package/system area for installation of cables supplied by vendor and for owner’s supplied cables, if any for the Additional Storage Tank for Liquid Pitch Handling,
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•
Earthing materials for equipment safety earthing, earthing grid for the complete Proposed Additional Storage Tank for Liquid Pitch Handling and its connection to purchaser’s earthing grid, located Inside/Outside the shop,
•
Lighting protection system material including earth electrodes required for conveyor galleries, silos and high structures pertains to proposed Additional Storage Tank for Liquid Pitch Handling etc. supplied by vendors. However, lighting protection of Green Anode Plant/building shall not be done by owner.
•
Fabrication, supply, erection and painting of steel structural supports required for various electrical equipment in Additional Storage Tank for Liquid Pitch Handling or pertains to Additional Storage Tank for Liquid Pitch Handling,
•
All automation equipments like PLC, Flow Meter, Temperature Sensor, Solenoid Valves etc. shall be supplied by the vendors.
•
Commissioning spares.
•
Construction of a MCC Room
Erection, Testing , Commissioning: Vendor scope shall include erection, testing, commissioning and performance test & guarantee of all equipment/material covered in clause 3.3 above.
3.5
Miscellaneous Activities The vendor’s scope of work shall also include, •
Obtaining approval from Electrical Inspector for installation and energisation of complete electrical facilities of the proposed Additional Storage Tank for Liquid Pitch Handling. Vendor shall also obtain/ produce required valid license from Electrical Licensing Board, Orissa within three months of award of the Contract/ Brief Order but in any case before start of electrical works at site failing which the contract may be liable for cancellation. Any delay on this account shall not relieve vendor of the responsibility to complete the Project within the overall time schedule.
•
All modification or additional requirement suggested by Electrical inspector shall be carried out by contractor at his own cost without affecting project time schedule.
•
Obtaining any other statutory approvals if required.
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Guaranteed Spares: Vendor shall supply the guaranteed spares for two years of trouble-free operation for the complete electrical system. Any shortfall in spares during these two years of operation shall be made up by vendor without any cost and time implications to Owner in line with the clause for “Guaranteed Spares” specified in P.R.
4.0
EXCLUSIONS FROM VENDOR’S SCOPE •
415VAC TPN SFU or ACB to feed the Vendor’s Main Switchboard (MCC).
•
451V AC feeders for feeding vendor’s lighting panels.
•
General lighting for main roads and access roads rear the Green Anode Plant /Building and general illumination inside Green Anode Plant /building.
•
However vendor shall asses the requirement themselves in consultation with Nalco for exact requirement and estimate before offering quotation.
5.0 TECHNICAL SPECIFICATION System Voltage and Frequency Principle voltage levels for power distribution and utilization a) 415V AC (nominal), 3-Phase 3/4-Wires, 50Hz, Solidly Earthed Neutral: This voltage shall be used for all motors above 0.37 KW all other three phase loads e.g. power sockets etc. b) 240V AC (nominal) 1-Phase 3-Wire, 50Hz, Solidly Earthed Neutral: This voltage shall be used for low power single phase loads such as lighting, small power receptacles, motors rated below 0.37KW etc. Voltage and Frequency Variation The following maximum variation shall be considered for equipment design: a) Voltage: Differing from its nominal value by not more than ± 10% b) Frequency: Differing from its nominal value by not more than ± 3% Design Ambient Temperature The design ambient temperature for electrical equipment will be 50 º C.
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All 415 V AC Motors shall be provided with Local Power Isolation Cabinets or Load Break Switch containing Isolator with visible break. However, all MV power and control cables to be used for interconnecting equipment supplied shall be of unarmoured typed. Flexible copper cables conforming to IEC-228 Class –5 shall be used for connection between local power isolation cabinets or (LBS) and 415V motors. The cable sizes for motors indicated in above data sheet are the minimum requirements. Vendor shall check adequacy of these sizes based on actual cable lengths, during detailed engineering and provide cables of increased sizes, if required. GI strip shall be used for earthing system and lighting protection system. The size of earthing conductor to be used for main earth grid shall be 50x6 mm. The size of horizontal air termination and down conductor shall be 20x5 mm. All hardware necessary for interfacing control system signals with all motors starters shall be in Vendor’s scope. Local control station shall be provided near each motor for local operation. Separate control cables shall be used for AC circuits and DC circuits for interfacing signals between 415V AC (MCC) Switchboards and Microprocessor based control system, wherever applicable. Inopportune Tripping When voltage drop occurs or short power cuts occur following precautions shall be taken in design. a. If the contractors are likely to open in an order which might be dangerous for personnel or equipment, a minimum voltage device shall be provided to switch off complete in sequence at given voltage level. b. For installations which as per vendor’s requirement must continue to operate, transient voltage drips or short power cuts shall be provided with capacitor charged system to keep the contractor closed for specified short duration. Emergency Stop push buttons shall be suitably distributed throughout the installation and positioned so as to be clearly visible and readily accessible. Emergency stop command shall be permit the stoppage without delay, by acting to trip the main contractor /circuit breaker. Motors in general shall be asynchronous squirrel cage type having synchronous speed of 1500 rpm. Suitable canopy shall be provided for all outdoor motors.
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In control rooms with false ceiling GI conduits for lighting shall be installed above false ceiling. The illumination level shall be minimum 450-500 lux at reading level of control panels/ desks and minimum 300 lux around the racks / cabinets behind panels, other areas. Sufficient care shall be taken to avoid glare reflection on VDU screen if applicable. General illumination level in the plant/ shed areas, etc. shall be minimum 100 lux for highbay type lighting fittings, 20% extra lighting fittings over and above required as per lighting design shall be provided to take care of maintenance intervals, etc. HPSV lamps shall be used for general illumination of outdoor areas, plant / shed areas, etc. Lighting shall additionally be provided, if required for specific equipment area, walkways, and platforms in the shop. Fluorescent tube light fittings shall not be used in plant areas including conveyor galleries. 70W HPSV lamp fittings shall be used for conveyor galleries, walkways in the shops, etc. However, Fluorescent tube light fittings would be used in switchgear room, control rooms, offices, rest rooms, etc. Suitable type of lighting fixtures (IP65 Enclosure) shall be used to take care of dusty environment in the conveyor gallery & other areas such as silos, stairs, etc. Vendor shall furnish the type and details of lighting fixtures used for this application along with the offer. In view of presence of large quantities of dust in the shops, various electrical panels/cabinets (e.g. control stations, welding receptacle cabinets, local control panels, etc.) shall have IP-65 degree of protection and shall be provided with special constructional features to have projecting roof/canopy to avoid falling of dust inside the electrical cabinet while opening the panel door during operation/ maintenance. Designed shall be made such that minimum possible number of enclosure shall be installed in the shop floor and maximum number of enclosure shall be installed in the control room/MCC room. Due to presence of large quantities of dust inside the shops, horizontal cable trays on which dust accumulates shall not be used. Cable trays supports shall be able to bear the weight of a man without giving way or being permanently deformed. Minimum vertical clearance between two cable trays shall be 250 mm. MCC switchboard shall be drawout, single front type. However, if required during detailed engineering, double front MCC shall be supplied without any cost and time implications. H.D. switch at MCC incomer shall be suitable for fault level of 50 KA (for 1 sec.). Atleast 20% spare outgoing feeders, subject to a minimum of 1 of each type and rating shall be provided in MCC Switchboard for FVNR/FVR feeders, type and rating designation (e.g. FVNR-15, FVR-15, FVNR-15 HD etc. as per M.V. switchboard data sheet) shall be considered for working out number of spares. For switch fuse feeders switch rating shall be considered for working out number of spares.
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The Motor Control Centers (MCCs) shall include motor feeders of all rating. The maximum rating of busbar shall be limited to 800A. Heavy duty type load break switches shall be used for incoming feeders. The required nos. of MCCs shall be decided by vendor on the above basis. MEMORANDUM OF UNDERSTANDING It may be noted that Nalco has complete Memorandum of Understanding (MOU) with Nalco enlisted indigenous manufacturers for Power & Control cables and MV motors regarding compliance with Nalco standard specifications. Vendor shall ensure that there are no deviations to Nalco standard specifications, except those as per MOU with respective manufacturer. ‘Y 2 K’ COMPLIANCE REQUIREMENTS Vendor shall confirm that the delivered product, software and system and system are year 2000 compliant i.e. that neither the performance nor functionally of the product, software or system, operating alone and or together with other products, software and/or systems are or will be affected by dates prior to during and after year 2000 in particular: No value for current date will cause any interruption in the operation of the product, software system. -
The product, software and system shall calculate, manipulate and represent all data values within the application domain correctly for the purposes for which they are intended.
-
In all interfaces and data storage, the century in any date is specified either explicitly or by unambiguous inference rules, and
-
The product, software and system recognize the year 2000 and all the leap years beyond the year 2000, as leap years.
UPS system shall be non-redundant type with by-pass circuit. Batteries shall be SMF VRLA type with a back –up time of 30 minutes. UPS shall be located in control room. Local power isolation cabinet’s alongwith load break switch shall be rated for the applicable fault level and comply with specifications of P.R. These shall be of FERRAZ (CEFEM) or SOCOMEC make only. 6.0 LOCAL POWER ISOLATION CABINET WITH LOAD BREAK SWITCH Local power isolation cabinet shall contain a load break switch of sufficient rating for motor duty to cut off power ‘on load’ with visible open contacts, which shall be located in the vicinity of each motor.
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Load Break Switch shall be housed in cast aluminium or sheet steel cabinet having enclosure protection of IP-65 class and with suitable gasketing by providing neoprene gasket etc. Load break switch shall be heavy duty air break and shall have quick make/break manual operating mechanism. The switch shall be of motor duty AC23 type only. The operating handle shall be mounted on the door of the cabinet. It shall be possible to padlock the switch in OFF position. Three padlock with duplicate keys shall be provided alongwith the local power isolation cabinets. Door interlock shall be provided so that it shall be not possible to open the door with switch in ‘closed’ position. Normally it shall not be possible to close the switch with door open, but for testing purposes it shall be provided to prevent inter-phase arcing. The live terminals shall be shrouded to avoid accidental contract. The load break switch shall be provided with an auxiliary pre-break contract (micro –switch) for using to open the corresponding contractor control circuit before opening the switch. The push button cabinet and the ‘load break switch’ cabinet be combined into one cabinet as and when it is so desired.
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7.0 LIST OF ATTACHMENTS Data Sheets/ Formats Attached Sl.No. a. b. c. d. e. f. g. h.
i.
Description MV Switchboard – MCC data sheet Data Sheet for MCCs MV Switchboard Data Sheet –Incomer, etc. Cable data sheet Electric load data Data sheet or MV motor Acceptable vendors : Electrical equipment Approved makes: Components/ Installation material Power cable sizes for 415V motors
Data Sheet Number
Specifications Attachment S.No. a. b. c.
Description M.V. Switchboard (Drawout type ) Medium voltage induction motor Offsite package units
Specifications No.
Drawing Attached S.No. a.
Description Key SLD – Power Distribution Scheme Additional Storage Tank for Liquid Pitch Handling
Drawing No.
Vendor Data/Documents Required S.No. a.
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Description Vendor Data requirement (Electrical)
Documents No.
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DATA SHEET FOR MCC PART –I (TO BE FURNISHED PURCHASER) 1.0
SITE CONDITIONS Maximum ambient temp: 47.2 °C Minimum ambient temp: 5.5 °C Design
: 50 °C
Relative humidity Rainfall
: Max. 83%, Average (yearly) 51% : Max. 80 mm/hr, Max. 257.3 mm/day. Max.2148.7 mm/annum
Altitude above MSL : 116 m Location
: Nalco Smelter Division, Carbon Plat, Angul.
Atmosphere
: Tropical and humid
2.0 OPERATING CONDITIONS : Voltage
: 415 V ± 10%
Frequency
: 50Hz ± 3%
No of phases
: Three
System fault level
: 50 kA for 1.0 sec.
System earthing
: Solidly earthed
Auxiliary supply AC
: 240 V AC, 1-Phase 50 Hz
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3.0 ELECTRICAL DATA 1 sec short circuit : 50 kA withstands capacity Busbar current rating inside : As per vendor/SWBD data sheet Panel at specified ambient Busbar
: Sleeved
Provision of Earthing Switch truck
: Not required
System breaking capacity
: 50kA
System making capacity
: 105 kA (peak)
Type of CB
: Not applicable
Duty cycle of breaker
: Not applicable
Suitability of capacitor Switching
: Not applicable
Incoming power entry
: Cables/As per data sheet
Cable entry (I/C &O/G)
: bottom
Bus duct entry
: Not applicable
Cable gland /lugs
: Included
IDMTL relay type
: Not applicable
Color shade exterior Interior
: Epoxy/631 as per IS-5 : Synthetic enamel finish/631
Feeder arrangement
: Single front, draw out type
Floor fixing
: Integral base frame.
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PART –II (TO BE FILLED UP BY VENDOR ALONG WITH QUOTATION) MCCs 1.0 Make
:
2.0 Type/ designation 3.0 Degree of protection
: :
4.0 Overall weight of CB panel Incomer : Outgoing :
kg kg
5.0 Overall dimensions of CB panel 5.1 Length : Depth : Height :
mm mm mm
NOTE: Vendor shall furnish the dimensions of various types/ratings of CB panels separately. Overall dimensions of MCC/ Contractor controlled feeder panel Length : mm Depth : mm Height : mm 6.0 6.1 Overall dimensions of MCC/ Length : Depth : Height :
mm mm mm
6.2 Overall weight and dimensions of largest shipping section: Length : mm Depth : mm Height : mm 7.0 Recommended clearances for SWBD Front Rear Above
: : :
mm mm mm
8.0 Shock loading on foundation : 9.0 Max size/no. of PVC
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Insulated Al Conductor (AYFY) cables that can terminated inside the panel with rear extension/without rear extension: 10.0
Clearance in air Phase to phase Phase to earth
: :
mm mm
11.0 Main horizontal bus bar
:
11.1 Busbar current rating at Design ambient (: 50 °C)
:
11.2 Main bus bar size
:
A mm²
NOTE: Busbar size shall be specified for various bas bar current ratings. 11.3 Main bus bar material 11.4 Main bus bar location
: :
12.0 Vertical bus bar Current rating/ Size/Material
Al/Cu Top/Bottom
:
13.0 Insulating material
:
14.0 Earth bus size/material :
mm²/Al/Cu
15.0 1 minute power frequency voltage: 16.0 1 sec short circuit withstand capacity: 17.0 Peak dynamic withstand capacity: 18.0 Safety shutter provided for Test and Drawout positions :
kV kA kA Yes/No
19.0 If Yes, furnish dimensions : 20.0
21.0 21.1 21.2
SMELTER DIVISION
Whether dummy panel required for maintaining 6000 mm Centerline distance between the two incomers for bus duct entry :
Yes/No
CIRCUIT BREAKER Make: Type designation: DOCUMENT TITLE
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21.3
No of poles/phase:
21.4
Nominal current rating (in free air ) :
21.5
A at º C
Current rating at site Conditions (inside panel):
A
21.6
a) Breaking capacity : ( MVA at b) % DC component :
21.7
kA kV) sysm
Short time rating (1 sec): (
21.8
Peak Making Current
:
21.9
1 min dry withstand volt (Power frequency) :
21.10 Duty cycle
kA MVA at kV) unsysm kA(peak)
:
21.11 Total opening time
:
m sec
21.12 Total closing time
:
m sec
21.13 Power required for opening
:
W/VA
21.14 Power required for closing
:
W/VA
21.15 Power required for spring charging motor
:
W/VA
21.16 Breaker is trip free
Yes
:
21.17 Closing mechanism 21.18 Provision of manual spring charging
: :
Yes
21.19 Tripping mechanism
:
21.20 Mechanical trip PB provided
:
21.21 Mechanical ON/OFF indicator provided :
Yes
21.22 Operation counter provided
:
21.23 Time taken for spring charging sec.
:
21.24 No. of auxiliary contacts and their current ratings
:
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Yes
Yes/No
NO + NC
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(Without multiplying a contact) 21.25 De-rating required for Capacitor Switching :
%
NOTE: Above particulars are required for each rating of breakers offered. 22.0
CONTACTOR
22.1
Make
:
22.2
Type Designation
:
22.3
Rated Voltage
:
22.4
Rated Current AC-3 Duty AC-4 Duty
: :
22.5
Thermal rating
:
22.6
Making capacity
:
22.7
Breaking capacity
:
22.8
Power factor
22.9
DC rating
: :
22.10 Switching frequency
:
ops/hr
Electrical
:
ops
Mechanical
:
22.11 Life
22.12 Coil consumption – pick up
:
(at rated voltage) Ops VA at ft
22.13 Coil consumption – Hold on
:
VA
22.14 Closing time
:
Seconds
22.15 Opening time
:
Seconds
22.16 No of aux. contacts
:
NO + NC
23.0
SWITCH
23.1
Rated Voltage
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23.2
Rated Current
:
23.3
AC-23 Rating
:
23.4
Rated making capacity
:
23.5
Rated breaking capacity
:
23.6
Rated short circuit withstand current with max. permissible rated fuses
23.7
Mechanical life
:
:
NOTE: Above particulars are required for each rating of switch offered. 24.0
THERMAL OVERLOAD RELAY
24.1
Make/type
:
24.2
Setting range
:
24.3
Single phasing preventor
24.4
Temp compensation feature
24.5
Type of operation
SMELTER DIVISION
: Provided/Not provided In –built/ Separate : Provided/Not provided : Direct/ CT operated
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CABLE DAT SHEET Part-1 (Data by Purchaser) PROJECT DATA Project Title / Ref. No. : Additional Storage Tank for Liquid Pitch Handling of GAP Location /Client
: Angul, Orissa/ Smelter Division, M/s Nalco Ambient Temperature : Max = 47.2 º C Min = 5.5 º C Design Ambient Temperature : 50 º C Nominal Voltage of the System: 415 V AC Highest System Voltage/ : 415 VAC±10 % /50 kA for 1 Sec System Fault Level Frequency : 50 Hz ± 3 % Voltage Grade Earthed System : 1100 VAC Unearthed System : NA Single Phase to Ground : NA Fault Current / duration (applicable to high voltage cables) Whether tinning required : NO For copper cables Whether Heat Resistant PVC : As required in some place Required for MV Power/Control Cables Whether Flame retardant : YES PVC required for PVC /XLPE Cables Local Load Break : PVC Insulated Copper Flexible Switch (LBS) to Motor Cable Power Cable Make of Cables : LAPP/Finolex
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CABLE DAT SHEET Part-2 (Data by Vendor) GENERAL Name of Manufacturer: Cable type/ Code Technical Particulars (To be furnished separately for each size) Thickness of insulation : Thickness of inner sheath: Calculated diameter of : cable under armour (as per IS: 10462) Type and size of armour : Nominal diameter of : cable under outer sheath Calculated diameter : of the cable under outer sheath Thickness of outer sheath: Nominal outer diameter of Cable. Tolerance on outer diameter: Type of Compound for : Conductor insulation, Inner sheath and Outer sheath. Maximum drum length of : Cable
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STANDARD SPECIFICATION FOR M.V.SWITCHBOARD (DRAW-OUT TYPE)
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CONTENTS 1. SCOPE 2. CODES AND STANDARDS 3. SITE CONDITIONS 4. DESIGN AND FABRICATION REQUIREMENTS 5. SPECIFIC REQUIREMENTS OF CIRCUIT BREAKER PANELS 6. SPECIFIC REQUIREMENT OF MCC PANELS 7. SWITCHGEAR MODULES 8. SWITCHBOARD COMPONENTS 9. TEST AND ACCEPTANCE 10. PACKING AND TRANSPORT
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1.
SCOPE
1.1
This specification covers the requirements of design, manufacture, testing, packing and supply of Medium Voltage Draw-Out Type Switchboard consisting of Power Control Center (PCC), Motor Control Centre (MCC). Auxiliary Service Boards (ASBs) and Power-Cum-Motor Control Centre (PMCC) required for receipt, control and distribution of power to various medium voltage equipment of the project.
1.2
PCCs/ PMCCs would receive power from the secondary windings of distribution Transformers and would distribute the same to MCCs, Auxiliary Service Boards and other consumers with running loads above 100 Amps and medium voltage motors rated for 75 KW and above. PCCs/ PMCCs would generally have air circuit breaker feeders, large motor starter feeders and large switch fuse unit feeders.
1.3
MCCs would receive power from PCCs/PMCCs and distribute the same to medium voltage motors up to and including 55 KW unless otherwise specified in data sheets. MCCs would generally have motor starter feeders and a few Switch Fuse Unit (SFU) Feeders.
1.4
ABSs would receive power from PCCs/PMCCs and distribute the same to individual medium voltage equipment of ratings upto 100 Amps. ASBs would generally have switch fuse unit feeders and switch fuse contractor feeders.
2.
CODE AND STANDARDS
2.1
The switchboard assembly shall conform to following Indian Standards.
2.1.1 IS: 5578
Guide for marking of insulated conductor.
2.1.2 IS: 8623 Factory built assemblies of switchgear and control gear for voltages upto and including 1000 V AC and 1200 V DC Part -II particular requirement for busbar trunking system (Bus Ways) 2.2
The individual equipment mounted in the switchgear shall conform to the following Indian Standards. IS: 772 Part-I AC Electricity Meters: Part-I general requirement and tests (second revision) IS:
1248 Direct acting electrical indicating instruments (first revision)
IS:
2705 Current transformers:
IS:
3156 Voltage transformers :
IS:
3231 Electrical relays for power system protection
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IS:
3618 Phosphate treatment of iron and steel for protection against corrosion.
IS:
5082 Material data for aluminum bus bars.
IS:
6005 Code of practice of Phosphating iron and steel.
IS:
11353 Guide for uniform system marking and identification of conductors and apparatus terminals
IS:
13703 Low voltage fuses.
IS:
13947 LV Switchgear and control gear. (Part-I to Part-5)
3.
SITE CONDITIONS
3.1
The switchboards shall be suitable for installation and satisfactory operation in a Pressurized or without-Pressurized substation with restricted natural air ventilation in a tropical, humid and corrosive atmosphere. The switchboards shall be designed to operate under site conditions as specified in the data sheets. If not specifically mentioned therein a design ambient temperature of 50 º C and altitude not exceeding 1000 meters above mean sea level shall be considered. The Enclosure of the Switch Board shall be IP 54 Minimum.
3.2
All the equipment described in this specification is intended for continuous duty at the specified rating under the specified ambient conditions unless indicated otherwise.
4.
DESIGN AND FABRICATION REQUIREMENTS
4.1
Medium voltage switchboard shall be metal enclosed fully Draw-Out, Free Standing, Floor Mounting, Single Front, Compartmentalized, Modular Type suitable for indoor installation. The switchboard enclosure shall be dust and vermin proof and shall provide a degree of protection of not less than IP: 42.
4.2
The switchboard shall be assembled out of vertical panels of uniform height.
4.3
It shall be possible to extend the switchboards, in either direction at a future date. Ends of bus bars shall be suitably drilled for this purpose. Panels at extreme ends shall have openings which shall be covered with plates screwed to the panel. Details of drilled holes in bus bar and openings in the panels provided for future extension shall be clearly shown in the vendor drawings.
4.4
The switchboard shall be designed to ensure maximum safety during operation, inspection, connection of cables, relocation of outgoing circuits and maintenance, with the bus bar system energized and without taking any special precautions. Means shall be provided to prevent shorting of power and/ or control terminals due to accidental dropping of maintenance tools etc. inside the switchboard. Checking and removal of components shall be possible
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without disturbing adjacent equipment. All auxiliary equipment should be easily accessible. 4.5
All identical equipment and corresponding parts shall be fully interchangeable without any need for resorting of structural modification.
4.6
The frame, of individual vertical panels shall be fabricated using pressed and shaped cold rolled sheet steel of adequate thickness or by using suitable mild steel structural sections. The sheet steel used for panel shall be of minimum 14 SWG CRCA except that the doors and covers may be made of 16 SWG CRCA. Wherever required, stiffeners shall be provided to increase stiffness of large size doors and covers.
4.7
The switchboard shall be provided with integral base frame for each vertical panel. The switchboard integral base frame shall be suitable for directly bolting with the help of foundation bolts and shall also be suitable for tack welding to the Purchaser's floor embedded channels.
4.8
All openings, covers and doors shall be provided with neoprene Gaskets. Blanking plates shall be provided for all sizes of modules to cover the openings in the event of withdrawing the feeder modules.
4.9
All hardware shall be corrosion resistant. All joints and connections of the panel members shall be made by cadmium plated high quality steel bolts, nuts and washers secured against loosening. Star washers shall be used to ensure to ensure effective continuity.
4.10
Suitable removable type lifting hooks and or jacking pads shall be provided on each panel or shipping section for ease of lifting of switchboard. These hooks when removed shall not leave any opening in the panels.
4.11
All power and control cables shall be terminated by purchaser through single compression nickel-plated brass cable glands. All cable glands and tinned copper crimping type cable lugs (power and control) shall be in vendor's scope of supply. Panels shall be suitable for bottom entry of cables unless otherwise specified.
4.12
Non-Magnetic cable gland plates shall be provided for termination of single core cables.
4.13
The switchboard shall be formed using distinct vertical panels each comprising of following compartments.
4.13.1 A metal enclosed horizontal busbar compartment running horizontally at top unless otherwise specified. 4.13.2 Individual feeder modules in multitier mode.
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4.13.3. Vertical bus bars serving all feeder modules in the vertical panel. The vertical bus bars shall be sleeved and provided with anti-tracking barriers an integral part of bus bar zone. 4.13.4 Cable termination compartment. 4.13.5. Perforated sheet steel/ insulating material enclosed horizontal auxiliary busbar for control, interlock, indication and metering wiring running horizontally. 4.14
Metal sheets shall be provided between two adjacent vertical panels running upto full useful height of the switchboard. In the cabling chamber shrouds shall be provided on the side of vertical bus bars.
4.15.
MCC shall be of single front execution as specified in the Material Requisition (MR). Circuit breaker panels shall be in single front execution only. Access to all operating devices shall be from the switchboard.
4.16
All metering and protection equipment associated with a particular circuit shall be housed in separate and independent compartment earmarked for that particular circuit and in the fixed portion of the vertical panel in case of breaker panels.
4.17
All auxiliary devices for control, indication, measurement and protection such as Push Buttons, Control and Selector Switches, Indicating Lamps, Ammeters, Voltmeters, KWH meters and Protective Relays shall be mounted on the front side of the respective compartment only. However mounting of some of these devices on the trolley may be accepted provided necessary blanking plates are provided to cover the opening left in the panel door when trolley is withdrawn out of panel. The design shall be such that unless required for maintenance/inspection purposes, all power On/Off or Start/ Stop and Relay reset operations shall be performed without opening the panel door.
4.18
Space heaters The switchboard panels shall be provided with space heaters to prevent moisture condensation. The space heater with porcelain connectors shall be located at the bottom of each panel and shall be supplied from 240 V AC auxiliary buses for space heater. The space heater shall be provided with a manually operated switch and HRC fuse and link for phase and neutral respectively.
4.19
SMELTER DIVISION
Auxiliary Bus Bars
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Auxiliary bus bars each of minimum size 18 ² mm copper shall be provided for following applications. Exact number of bus bars shall depend on various control, metering and auxiliary power distribution requirements specified in material requisition. 4.19.1
Panel space heater supply and motor space supply
4.19.2
Control supply for breaker tripping, closing and indication circuits.
4.19.3
Control supply for breaker spring charging motors, motor starter control and indication circuit.
4.19.4
AC potential supply for KWH meters. Tee-Off connectors shall be used for distributing auxiliary supply to each vertical panel. Rubber grommets shall be used for all wire entries to make the entries dust and vermin proof. Isolating links/fish plates shall be provided between two auxiliary bus sections.
4.20
Bus Bar
4.20.1
Busbars shall be of high conductivity aluminum (E91E) supported on insulators made of non-inflammable material with tracking index equal to or more than 600 mm as per IEC-112. The main busbars shall have uniform current ratings throughout their length as indicated in the switchboard data sheets. The current rating of the neutral shall be half that of the phase busbars. Removable neutral links shall be provided on feeders to permit isolation of the neutral busbar.
4.20.2
Both horizontal and vertical bus bars, bus joints and supports shall be cable of withstanding dynamic and thermal stresses of the specified short circuit currents for 1 second. Only zinc passivated or cadmium plated high tensile strength steel bolts, nuts and washers shall be used for all bus bar joints and supports. The short circuit capacity of the neutral bus bars shall be in line with IS: 13947.
4.20.3
The hot spot temperature of bus bars including joints at design ambient temperature shall not exceed 90º C for normal operating conditions.
4.20.4
The current rating referred in the data sheets are for design ambient temperature at site conditions and for being inside the cubicle at fully loaded condition. The vendor shall suitable de-rate the nominal rating to suit the above condition.
4.20.5
All bus bar shall be insulated with heat shrunk PVC sleeves of 1100 V grade. Red yellow and blue colour shall be used for phase bus bars and black colour shall be used for neutral bus bars. Joints shall be shrouded suitably.
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4.20.6
Minimum clearance between live parts, between live parts/neutral to earth shall be 19 mm. However clearance at components shall be as per individual standards.
4.20.7
Interconnections between the main bus bars and individual units shall be made by using vertical aluminum bus bars of adequate rating. These interconnection and the vertical bus bars shall be compartmentalized and fully shrouded. Vertical bus bars for circuit breaker panels shall be sized depending upon the rating and number of breakers per vertical panel. Vertical bus bars for MCC panels shall be of uniform cross section. Size of vertical busbars for MCC panels shall not be less than 50 x 10 mm Aluminum per phase. All joints surfaces at aluminum to copper joints shall be silver/tin plated, alternatively Cu-Al washers (bimetallic washers) may be used. Minimum size of busbars for starter/ feeder power connections above 100 Amp rating shall be 20 x 6 mm Aluminum.
4.21
Wiring and Terminals
4.21.1
Inside the switchboards the wiring for power, signaling, protection and instrument circuits shall be done with BIS approved PVC insulated copper conductors. The insulation grade for these wires shall be 660 volts grade. All control wiring shall preferable be enclosed in plastic channels or neatly bunched together.
4.21.2
PVC insulated copper conductor of cross section 1.5²mm may normally be used provided the control fuse rating is 10 amps or less. For 16 amps control fuse circuit 2.5 mm² copper conductors shall be used. Each wire shall be terminated at a separate terminal. C.T. circuit wiring shall be done with 2.5 sq mm. Copper conductor. Shorting links/suitable shorting arrangement for shorting CT secondary shall be provided.
4.21.3
Each wire shall be identified at both ends by PVC ferrules.
4.21.4
Inter panels wiring within each shipping section of the switch board shall be vendors responsibility. For wiring between shipping sections, vendor shall provide terminal blocks on adjoining shipping sections and supply suitable jumpering wires. Inter-panel wiring shall be taken thorough PVC sleeves or rubber grommets.
4.21.5
A minimum of 10% spare terminals shall be provided on each terminal block. Conductors shall be terminated with adequately sized compression type lugs. Clamp type terminal for direct conductor termination shall be acceptable for wires unto 10 mm² size and bolted type terminals with crimping type copper lugs shall be provided for all outgoing cable connections large than 10 mm².
4.22
All vertical panels shall be connected to a tinned copper earth busbar running throughout the length of the switchboard. The minimum earth bus size shall be 300 mm² tinned copper. All doors and movable parts shall be earthed using flexible copper connections to the fixed frame of
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the switchboard. Provision shall be made to connect the earthing busbar to the plant earthing grid at two ends. All non-current carrying metallic parts of the mounted equipment shall be earthed. Minimum 4 nos. 10 mm diameter bolts with nuts shall be provided on the earth bus for termination of fourth core of cable per vertical panel. 4.23
Name Plate A nameplate with the switchboard designation shall be fixed at the top of the central panel. A separate nameplate giving details for each compartment of bus section shall be provided. Nameplate or polyester adhesive stickers shall be provided for every equipment (lamps, push buttons, switches, relays, auxiliary contractors etc.) mounted on the switchboard. Special warning plate shall be provided on removable covers or doors giving access to cable terminals and busbars. Special warning labels shall be provided inside the switchboards also, wherever considered necessary. Identifications tags shall be provided inside the panels matching with those shown on the circuit diagram. Engraved nameplates shall preferably be 3 ply (Black-White-Black) lamicoid sheets or anodized aluminum. However back engraved perspex sheet nameplates may also be acceptable. Engraving shall be done with square / vee groove cutters. Hard paper nameplates shall not be acceptable. Nameplates shall be fastened by screws and not by adhesives. The name plates for feeder compartments shall be in two parts. One part shall have necessary details pertaining to the switchboards. The other parts shall be removable and shall contain all details regarding the drives/equipment controlled by the particular module.
4.24
Painting
4.24.1
All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rest, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and coat of yellow zinc chromate primer. The under surface shall be made free from all imperfection before undertaking the finishing coat.
4.24.2
After preparation of the under surface, the switchboard shall be spray painted with two coats of epoxy based final paint or shall be powder coated. Colour shade of final paint shall be as per manufacturer standard unless specified other wise in the MR. The finished panels shall be dried in ovens in dust free atmosphere. Panel finish shall be free from imperfections like pinholes, orange peels, runoff paint etc.
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4.24.3
All unpainted steel parts shall be cadmium plated or suitably treated to prevent rust formation. If these parts are moving elements then they shall be greased.
5.
SPECIFIC REQUIREMENTS OF CIRCUIT BREAKERS PANELS
5.1
The breaker panels shall have distinct bus bar breaker and cable compartments. The design of each compartment shall be such as to prevent movement of vermin from a particular circuit breaker compartment to any other portion of the panel when the breaker is withdrawn and compartment door is closed. In order to minimize accidental access and avoid accidents due to falling tools, all the outgoing links shall be shrouded. Blanking plants shall be provided for circuit breaker compartments which would be used after installation to cover the openings in the event of withdrawing the breaker outside the compartment.
5.2
Outgoing ACB's can be mounted in a maximum of two tier execution while the incoming/ bus coupler ACB's shall be in single tier execution only. The KWH meter and protection relays associated with a particular breaker shall preferably be mounted on the same panel front.
5.3
Separate compartment totally enclosed from all sides shall be provided for cable termination, on the rear side. Access to cables shall be from the rear side after opening the cabling compartment door. The incoming/outgoing cable termination shall be staggered for each circuit and barriers of sheet steel or insulating material shall be provided between terminations of two circuits such that maintenance on one circuit could be carried out while the other circuit is live. Suitable clamping arrangement shall be provided for cables and cable termination. Terminal blocks shall not be used for supporting the cable. The incoming supply for PCC/PMCC panels shall be through top entry bus ducts or through bottom entry single core or multi core Aluminum conductor cables. The outgoing cables shall have bottom entry unless otherwise indicated in MR. The cable termination shall be suitably sized for receiving specified number of cables per termination and provision shall be made for terminating each outgoing cable with a separate bolted connection. In case the total number of cables entering a particular panel can not be accommodated in the cabling compartment of PCC panels an extension panel shall be added to the cabling compartment for accommodating extra cables. The enclosure design of cabling shall be such as to prevent the movement of vermin from this compartment to any other part of the switchboard.
5.4
Circuit Breaker Compartment
5.4.1
The circuit breaker compartment shall be fully Draw-Out, that is, bus side & outgoing power and control connections shall be through Draw-
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Out contacts. Suitable guides shall be provided to facilitate easy withdrawal of the circuit breaker. All identical feeder compartments shall be interchangeable. 5.4.2
The current transformers for the ammeter/protection circuits shall be mounted on the fixed portion of the compartment. However, current transformers associated with built-in releases may be mounted on the breaker trolley. All terminals except wiping/sliding type control terminals shall be shrouded with plastic cover to prevent accidental contract. For direct termination -clip on shrouded type terminals shall be provided. There shall be three positions for the Draw-Out trolley viz.: a) "Full in " or "Service" position both power and control circuit shall be connected. This shall be the normal operating position of the circuit breaker. b) "Test Position” - The power contacts shall be disconnected in this position but the control connections shall not be disturbed, it shall be possible to close and trip breaker in this position. c) "Full out' Position - both power and control circuits shall be disconnected in this position and breaker removed from the cubicle. The circuit breaker shall be lockable in "service” and "test" position. Safety shutters shall be done with a "pin" or with scrapping earth connections. The earth connection shall make before the main power/ control contacts make and break after the power / control contracts are disconnected. Earthing connection through a plug and socket connection shall not be acceptable.
5.5
Interlocks Following interlocks shall be provided:
5.5.1
Compartment doors shall be interlocked against opening when breaker is in closed or ON condition. However, it shall be possible to defeat this interlock for inspection purposes.
5.5.2
It shall not be possible to push "in" a drawn out circuit breaker in closed condition or withdraw a circuit breaker in closed condition.
5.5.3
It shall be possible to operate a circuit breaker only in the defined "Full in" or "Service" and "test" position inside the panel. It shall not be possible to operate the breaker in intermediate positions while inserting or withdrawing circuit breaker.
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5.6
6.
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Any unused circuit breaker compartment shall be fully equipped and provided with compartment door, vertical bus bars and control terminals/ wiring etc. such that the same could be used for housing outing breakers in future without any modifications to the panel. SPECIFIC RQUIREMENT OF MCC PANELS
6.1
The design of feeder trolleys shall not change for single front or double front execution. Separate vertical bus bars shall be provided for each front. Identical feeder modules in both the fronts shall be interchangeable.
6.2
Each MCC panel shall have a separate cable alley. The width of this cable alley shall be sufficient to accommodate all the cables and shall have free access for cable terminations and in any case shall not be less than 200 mm. Cable alleys shall be provided with suitable doors. Sheet steel barriers shall be provided between individual compartment and cable alley. This barrier shall be provided with opening for power and control connections and it shall be possible to safely carryout maintenance work on cable connections to any one circuit in the cable alley with the bus bars and adjacent circuits live.
6.3
The outgoing feeder trolleys shall be fully Draw-Out and shall have the following features.
6.3.1.
It shall be possible to withdraw the trolley without having to unbolt or unscrew any power and control connections to the equipment mounted on the withdraw-able trolley.
6.3.2
Both power and control connection shall be Draw-Out type. However, the incomer and bus tie feeders with load break switches and control supply transformer modules may be in fixed execution.
6.4
Various compartment sizes in a vertical MCC panel shall be multiples of a basic dimension. However the minimum module size shall be 200mm for switch fuse feeder and 240 mm for contactor feeders. Vertical bus bars shall be pre-drilled at regular intervals for complete flexibility for changes in size of modules.
6.5
The trolley withdrawal shall be by means of crank and screw arrangement. Alternatively movement on guided rollers may also be acceptable. Plug in operation shall be independent of manual force. For Draw-Out type feeders of size equal to or greater than half the useful vertical height of panel. Positive clamping arrangement shall be provided on the top portion of the trolley in addition to clamping arrangement at the bottom, to ensure all round positive pressure on the power Draw-Out contacts once the trolley is plugged in. Power Draw-Out contracts shall preferable be located towards the bottom portion of each trolley. The trolley shall be lockable in fully plugged in position
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and devices shall be provided to ensure positive plugging in. In test position, power contacts shall be totally isolated and a device shall be provided for indication of test position. 6.6
All switch drives other than rotary switches, shall be lockable in both 'ON' and 'OFF' positions. The switches/moulded case circuit breakers shall be interlocked with the compartment door to prevent opening of the door when the switch/moulded case circuit breaker is in 'ON' position and to prevent switching on when the door is open. A defeat mechanism for this interlock shall also be provided.
6.7
The maximum height of the operating handle/switches shall not exceed 1900 mm and the minimum height not below 300 mm.
6.8
Unused modules in the panel shall be fully equipped with hinged door, power and control terminals for starter modules and cradle for future use.
7.
SWITCHGEAR MODULES
7.1
Switchboard data sheet indicates the total number of each type of feeders required on the switchboard completely assembled in one line up. Feeders of three main categories are identified as circuit breakers, switch-fuse and motor starters. Component ratings for starter/ switchfuse feeders are specified on the switchboard data sheets whereas typical data sheet include the requirement of circuit breaker feeders.
7.2
Fully Draw-Out modules required for motor control shall be following four types and internal control wiring of all starter modules of each type shall be identical for all ratings.
7.2.1
FVNR- Full Voltage Non-Reversing Starter with minimum 18 control terminals.
7.2.2 FVR- Full Voltage Reversing Starter with minimum 24 control terminals. 7.2.3
FVNR-HDFull Voltage Non-Reversing Heavy Duty starter with long starting time such as for compressors and fans etc. with minimum 18 control terminals.
7.2.4 SFU- Switch-Fuse-Unit Modules with no control terminals. 7.3
Minimum 2000 VA transformer shall be provided separately for each bus section for motor control circuit voltage. For MCC with two bus sections coupled by bus tie manual changeover switch shall be provided.
7.4.
The service designation and actual KW rating of each motor connected to starter modules shall be indicated on the single line diagram submitted for approval by the manufacturer. Hence actual requirements
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of fuse links/ overload relays could be known only after the approval of drawings and no price variation due to this shall be accepted. 7.5
To facilitate site modification due to changes in motor KW ratings and to minimize spares inventory, overload relays and power fuse links shall meet the following requirements. All bimetal overload relays shall be Independent Mounting type with connecting links rating for the maximum rating of the contractor in a starter module.
7.6
Heavy duty starters shall be provided with saturable type current transformer operated overload relay only, which shall be suitable for motor starting time of 15 -60 seconds.
7.7
All combination starter feeders shall meet the requirements of type -II co-ordination as per IS:13947.
7.8.
All identical modules shall be interchangeable.
8.
SWITCHBOARD COMPONENTS
8.1.
Circuits Breakers
8.1.1
Circuit breakers shall be air breaker, Draw-Out type. The ratings shall be indicated on switchboard data sheets. Circuit breaker for generator incomer shall be with four poles.
8.1.2
The circuit breaker shall be provided with series trip releases for overload and short circuit protection or relays as specified in the MR.
8.1.3
The circuit breakers shall be provided with mechanically operated emergency tripping device. This device shall be available on the front of the panel. Mechanically operated 'closing' shall be provided for all breakers except circuit breakers controlling motor feeders.
8.1.4.
The circuit breakers shall be provided with minimum 4 Nos. normally open and 4 Nos. normally close spare auxiliary contracts, wired and available for purchaser's use. The available spare auxiliary contacts shall be multiplied to have 4 NO + 4 NC contracts (minimum) if sufficient number of breaker auxiliary contacts are not available.
8.1.5
Circuit breaker position shall be indicated electrically. The following indicating colours shall be used. BREAKER 'CLOSE' BREAKER OPEN' BREAKER 'AUTO TRIP
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8.1.6
Circuit breakers positions (OPEN AND CLOSED) location (SERVICE AND TEST) and spring changed condition shall also be indicated mechanically.
8.1.7
Unless otherwise specified, all circuit breakers in the switchboard shall be provided with electrical power operating mechanism.
8.1.8. Operating Mechanism a) Electric power operating mechanism shall be wound motor spring charged stored energy type. However, manual operating mechanism may be of the spring charging stored energy type or the spring assisted type. For circuit breakers with electrical power operating mechanism, provision shall be made for manual spring charging. Closing time of circuit breakers with manual operating mechanism shall be independent of the speed of the operating handle. b) All stored energy operating mechanism shall be equipped with following features. I. Failure of springs, vibrations or shocks shall not cause unintended operation of breaker or prevent intended tripping operation. II. Closing of circuit breaker shall be prevented unless the spring is fully charged. III. All electrical power operating mechanisms shall be suitable for remote operation and shall be equipped with following features. IV. Provided with universal motor operable on AC OR DC control supplies V. Provided with emergency manual facility. The motor shall be automatically de-linked (mechanically) once the manual charging handle is inserted. VI. Closing operation of circuit breaker shall automatically initiate charging of the spring for the next closing operation without waiting for tripping of circuit breaker. VII. Closing operation shall be completed once the closing impulse is given and the first device in the control scheme has responded even though the control switch /PB is released provided no counter trip impulse is present. 8.1.9
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Circuit breaker trip and closing in case of electrically operated breakers and trip coil in case of mechanically operated breakers and circuit breaker indication shall be suitable for satisfactory operation on a control supply system indicated in data sheets. DOCUMENT TITLE
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8.1.10
Circuit breakers shall be provided with anti-pumping feature.
8.1.11
The breakers shall be trip free and shall be provided with a release to trip the breakers instantaneously if closed on to a fault.
8.1.12
Releases are not required to be provided with breakers where relays are used.
8.2
Switches
8.2.1
All switches or fuse switches shall be load break, heavy duty/motor duty air break type provided with quick make/brake manual operating mechanism. The operating handle shall be mounted on the door of the compartment having the switch.
8.2.2
Rating of heavy duty switches for a particular starter module shall be as indicated in the switchboard data sheet. Motor duty switches of smaller ratings meeting the requirement of AC 23 duty as per IS: 13947, may be acceptable in place of specified heavy duty switch rating for particular starter module only if, motor duty switches have been tested and certified for use with the large size of fuse link specified in the switchboard data sheet for the same starter module.
8.3
Fuses
8.3.1
Fuses shall be non deteriorating HRC cartridge link type. Diazed fuses are not acceptable.
8.3.2.
Power Fuses shall be pressure fitted type and shall preferable have ribs on the contact blades to ensure good line contact.
8.3.3
It shall be possible to handle fuses during off load conditions with full voltage available on the terminals. Wherever required fuse pullers shall be provided. The fuse base shall be so located in the modules to permit insertion of fuse pullers and removal of fuse links without any problem.
8.4
Contactors
8.4.1
The contactors shall be air break type, equipped with three main contacts and minimum 2 NO + 2 NC auxiliary contacts. The main contacts of a particular contactor shall have AC 3 ratings as shown in the relevant switchboard data sheet for that contract.
8.4.2
Unless otherwise specified, the coil of the contactor shall be suitable for operation on 240 V, 1 PH, 50 HZ AC supply and shall work satisfactorily between 65 to 110 % of the rated value.
8.5
Thermal Overload Relay
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Bimetal relays shall be provided for protecting the motor from thermal overload and all Bimetal Relays shall be of Independent Mounting type. Bimetal relays shall be manually reset type with the reset button brought out on the front of the panel. The reset push button shall be capable of being operated without opening the compartment door.
8.5.2
8.5.3
Bimetal relays shall be positive action ambient temperature compensated type with adjustable setting range.
8.5.4
Bimetal relays shall have built-in single phasing prevention feature which operate even with 50% rated current at the time of single phasing.
8.6
Moulded Case Circuit Breakers (MCCBs)
8.6.1
If specified in the MR, MCCB's shall be provided in the switchboards for circuit protection. MCCBs rating shall be as indicated in the switchboard data sheet.
8.6.2
MCCB's shall be provided with spring assisted quick make /break manually operated trip free mechanism. Wherever specified, MCCB shall be suitable for remote tripping operation and the tripping device shall be suitable for the specified control supply voltage.
8.6.3
MCCB's shall be provided adjustable type tripping device with inverse time characteristic for over load protection and instantaneous characteristics for short circuit protection.
8.6.4
‘ON' and 'OFF' position of the operating handle of MCCB's shall be displayed and the operating handle shall be mounted on the door of the compartment housing MCCB.
8.6.5
MCCB shall be provided with minimum 1 NO + 1 NC auxiliary contacts.
8.6.6
If specified in the data sheet, the MCCB's shall be provided with solenoid /motorized closing mechanism to make them suitable for remote closing operation. The closing solenoid /motor shall be suitable for specified control supply voltage.
8.6.7
MCCB's as part of motor starter mould shall be current limiting type.
8.7
RELAYS
8.7.1
All protective relays shall be back connected, Draw-Out type, suitable for flush mounting and fitted with dust right covers. However auxiliary relays in fixed execution are acceptable.
8.7.2
The protective relays cases shall have provision for insertion of test plug at the front for "testing and calibration" purposes. It shall be possible to test the relays without disconnecting the wiring and without
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withdrawing the relays. The insertion of the test plug shall automatically short circuit the CTS and permits extension of external power supply to the relay. 8.7.3
All protective relays shall be provided with hand reset type built in flag indicators. It shall be possible to reset the flag without opening the relay case.
8.7.4
Each protective relay shall be provided with minimum 2 nos. potential free contacts of required configuration.
8.7.5.
Each tripping relays shall be lockout type with hand reset coil cut-off contact. The tripping relay shall be suitable for satisfactory from 50% to 110% of the specified control supply voltage.
8.8
Instrument Transformer
8.8.1
Current transformer shall generally conform to IS: 2705. The CT ratio and ratings shall be as indicated in the switchboard data sheet. For general guidance the vendor shall note that the protective current transformer shall have an accuracy class "5p" and an accuracy limit factor greater than "10". However Cts for restricted earth fault and differential protection shall be of class "PS".
8.8.2.
Current transformers for instruments shall have an accuracy class 1.0 and accuracy limit factor less than 5.0. However accuracy class of 3.0 is acceptable for CTs meant for remote ammeters. The current transformers shall be capable of with standing the applicable peak momentary short circuit and the symmetrical short circuit current for 1.0 second and shall have a minimum rating of 10 VA.
8.8.3
The voltage transformers shall be cast resin type and shall be provided with primary fuses. Miniature circuit breakers with auxiliary contact shall be provided on the secondary side.
8.9
Measuring Instruments
8.9.1
All measuring instruments shall be of 96 x 96 mm square pattern, flush mounting type. Instruments shall be provided as indicated in the data sheets. All auxiliary equipments such as shunts transducers, CT's PT's etc. as required shall be included in the supply of the switchboard.
8.9.2.
All AC ammeters/voltmeters shall be of moving iron type with accuracy class of 1.5 as per IS: 1248. The range shall be as indicated in the data sheet Ammeters for motor feeder shall have a nonlinear compressed scale at the end to indicate motor starting current. Volt meter shall be suitable for direct line connection.
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8.9.3
The KW/KWH meter shall be suitable to measure unbalanced loads on 3Phase, 4 wire system. Test terminal block shall be provided for KWH meters. The accuracy class of KW/KWH meters shall be minimum of 2.5.
8.10
Control Switches
8.10.1
All control switches shall be rotary, back connected type, having a cam operated contact mechanism. Preferably phosphor bronze contacts shall be used on the control switches. They shall have pistol grip handles for circuit breaker control and knob type handle for other applications. Ammeter selector switches shall have make before break feature on its contacts. The selector switch shall generally have 4 positions for reading 3 phase currents and fourth position for OFF. The voltmeter selector switch shall also have 4 positions. There shall be used to measure phase to phase voltage and fourth shall be OFF position.
8.10.7
Remote/Trip/Off selector switch for the motor feeders shall be lockable in OFF position.
8.11
Push Buttons:
8.11.1
Push button colours shall be as follows: Stop/Open/Emergency Start/Close Reset/Test
-Red -Green -Yellow/Black/White
8.12. Indicating Lamps: 8.12.1
Indicating lamps shall preferably be suitable for 240 Volts AC. Lamps shall be provided with translucent covers to diffuse light.
8.13
Auxiliary Relays /Contactors
8.13.1
Auxiliary relays /contactors shall generally be used for inter locking and multiplying contacts. Auxiliary contact shall be capable of carrying the maximum anticipated current.
8.14
Timers
8.14.1
For reacceleration duty, timers unless otherwise stated, shall be pneumatic type and shall have adjustable time setting of 0-60 seconds. The time settings, where specified shall be accurately set before dispatch of the switchboard.
8.14.2
Timers for Auto-Transfer schemes shall be of static type with timing ranges suitable for the scheme employed.
9.
TESTS AND ACCEPTANCE
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9.1.
During fabrication, switchgear shall be subject to inspection by Owner or by an agency authorized by the Owner. Manufacturer shall furnish all necessary information connecting the supply of Owners inspectors.
9.2
All routine acceptance tests shall be carried out at manufacturer's work under his care and expense.
9.3.
Type tests, if asked in the data sheet shall be performed. Short circuit test shall be performed at CPRI and heat run test may be performed at manufacturer's works. Heat run test shall be performed at least on two vertical panels of the ordered switchboard.
9.4.
In addition, specific tests shall be conducted to check mechanical & electrical operation and switchboard wiring for conformance to Owner’s specifications and approved schematic diagrams.
9.5.
Stage inspection after the pretreatment and preparation of under surface and before final painting shall be carried out by Owner's inspector.
9.6.
Shop tests shall be witnessed by an inspector of Owner or of an agency authorized by the owner. Prior notice of minimum 4 weeks shall be given to the inspector for witnessing the tests.
9.7.
Acceptance Tests shall be as follows: a) A general visual check shall be carried out. This shall cover measurement of overall dimension, location, number and type of devices, terminal boxes, and location and connection of terminals etc. b) Manual and electrical operation of C.B. / relays shall be checked under the worst conditions of auxiliary supply voltage. c) Dry insulation test with power frequency voltage shall be conducted for the main and auxiliary circuits. d) Insulation resistance of the main and auxiliary circuits shall be checked before and after High voltage withstand test. e) Operation check shall be carried out for every control function as per the schematic diagrams by manually simulating fault conditions and operation of control switches/ relays etc. f) Relays shall be tested with secondary injection test equipment. g) For equipment bought from other sub-suppliers, certified test reports of tests carried out at the manufacturer’s works shall be submitted. Normally all routine tests as specified in the relevant standards shall be conducted by the sub-supplier at his works.
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h) Interchangeability of similar modules shall be checked on a random basis. This may be done on one module of each size. 10.
PACKING AND TRANSPORT This switchboard shall be shipped to site packed in wooden crates. They shall be wrapped in polyethylene sheets before being placed in crates to prevent damage to the finish. Crates shall have skid bottoms for handling.
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STANDARD SPECIFICATION FOR MEDIUM VOLTAGE MOTORS
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CONTENTS 1. SCOPE 2. STANDARDS 3. OPERATING CONDITIONS 4. PERFORMANCE 5. GENERAL REQUIREMENTS AND CONSTRUCTION DETAILS 6. MISCELLANEOUS ACCESSORIES 7. NOISE LEVEL 8. MOTOR VIBRATION 9. CRITICAL SPEEDS 10. PAINTING 11. INSPECTION AND TESTING 12. DRAWINGS AND DATA
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SCOPE This specification covers the design, manufacture and testing of three phase medium voltage squirrel cage induction motors.
2.
STANDARDS Unless they are at variance with the clauses of this specification, the squirrel cage induction motors and their components shall comply with the latest applicable Indian standards listed below. Where Indian standards do not exist, the relevant IEC, British or German (VDE) standard shall apply.
2.1
IS-325 Three phase induction motors.
2.2
IS-1076 Preferred numbers.
2.3
IS-1231 Dimension of three phases, foot mounted induction motors.
2.4
IS-1271 Insulating materials for electric machinery and apparatus in relation to their terminal stability in service, classification thereof.
2.5
IS-2148 Flame proof enclosures of electrical apparatus.
2.6
IS-2223 Dimensions of flange mounted AC Induction motors.
2.7
IS-2253 Types of construction and mounting of motors.
2.8
IS-2254 Dimension of vertical shaft motor for pumps.
2.9
IS-2968 Slide rails for electric motors dimensions.
2.10
IS-4029 Guild for testing three phase induction motors.
2.11
IS-4691 Degrees of protection provided by enclosures for rotating electrical machinery.
2.12
IS-4722 Specification for rotating electrical machines.
2.13
IS-4728 Terminal making for rotating electrical machinery.
2.14
IS-4889 Methods of determination of efficiency of rotating electrical machines.
2.15
IS-6362 Methods of cooling for of rotating electrical machines.
2.16
IS-6381 Construction and testing of electric apparatus with type of protection 'e'.
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2.17
IS-7389 Pressurized enclosure of electrical equipment for use in hazards area.
2.18
IS-7816 Guide for testing insulation resistance of rotating machines.
2.19
IS-8223 Dimensions and output ratings for foot mounted rotating electrical machines with frame numbers 355 to 1000
2.20
IS-8289 Specification for electrical equipment with type of protection 'n'.
2.21
IS-8789 Values of performance characteristics for three phase induction motors.
2.22
IS-9283 Motors for submersible pump sets.
2.23
IS-9628 Specification for three phase induction motors with type of protection 'n'.
2.24
IS-12075 Mechanical vibration of rotating Electrical Machines.
2.25
IS-12065 Permissible limits of noise level for rotating electrical machines.
2.26
IS-12802 Temperature rise measurement of rotating electrical machines.
2.27
IS-13529 Guide on effects of unbalanced voltages on the performance of the three phase cage induction motors.
2.28
IS-13555 Guide for selection and application of three phase induction motors for different types of driven equipment.
3.
OPERATING CONDITIONS:
3.1
Ambient condition: Motors shall be suitable for operating satisfactorily in humid and corrosive atmosphere found in Refineries and Smelter/Metallurgical plant. Service conditions shall be specified in the data sheet. If specifically not mentioned therein, a maximum of ambient temperature of 500 C and altitude not exceeding 1000 M above mean see level shall be taken in to consideration.
3.2
Frequency and voltage variations: Unless otherwise agreed, motors shall be designed for continuous satisfactory operation at rated output under the following conditions. a) The terminal voltage differing from it’s rated value by not more than ± 6 % or b) The frequency differing from it’s rated value by not more than ± 3 % or c) Any combination of (a) and (b).
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Starting:
Unless otherwise specified motors shall be designated for direct-online staring. Motors shall be designed for re-acceleration under full load after a momentary loss of voltage with the residual voltage being 100 % out of phase. Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds under cold conditions and 8 seconds under hot conditions. The starting time of the motor shall be less than the hot thermal withstand time (Time tE in case of increased safety motors) to permit application of conventional bi-metal relays or thermal release against locked rotor and overload condition. Unless otherwise specified, all motors shall be suitable for starting under specified load condition with 75 % of the rated voltage at the terminal. Motors shall be designed to allow the minimum numbers of consecutive starts as indicated below.
TABLE-I Starts No. of consecutive starts-up with initial temperature of the motor at ambient level (cold) No. of consecutive starts-up with initial temperature of the motor at full load operating level (hot) 3.4
Min. no. of consecutive starts 3
2
Direction of Rotation: Motors shall be suitable for either direction of rotation. In case, unidirectional fan is provided for motors, direction of rotation for which the motor is designed shall be permanently indicated by means of an arrow. A painted arrow shall not be acceptable. Directional arrow shall be manufactured from corrosion resistant material. When a motor is provided with bi-directional fan, a double headed arrow should be provided. Normally, clockwise rotation is desired as observed at facing the driving end. Ample space shall be provided at the terminal box of the motor for interchanging any two external power supply lead for obtaining the reverse phase sequence.
4.
PERFORMANCE:
4.1
Motors shall be rated for continuous duty (S1) unless otherwise specified.
4.2
The starting current (as % of rated current) shall not exceed 600% for motors up to and including 75 KW and 550 % for motors above 75 KW subject to tolerance.
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4.3
Starting torque and minimum torque of the motor shall be compatible with the speed-torque curve of the driven equipment under specified operating conditions. For heavy duty drives such as blowers, crushers etc. high starting torque motors shall be provided. In case where characteristics of the driven equipment are not available while selecting the motor, minimum starting torque shall be 110% of the rated value for the motor up to 75 KW and shall be 90 % of the rated value for motors above 75 KW.
4.4
The pull out torque at the rated voltage shall be not less than 175 % of the rated load torque with no negative tolerance. Unless otherwise agreed, the pull out torque shall not exceed 300% of the rated load torque. In case of motors driving equipments with pulsating load (e.g. reciprocating compressor) the minimum value for the pull out torque at 75 % of the rated voltage shall be more than the peak value of pulsating torque and the current pulsation shall be limited to 40 %.
4.5
The minimum value for the product of efficiency and power factors for motors rated up to and including 37 KW shall be as per IS: 8789. The minimum value for product of efficiency and power factors of 2-pole, 4pole and 6-pole motor rated above 37 KW shall be as given below: TABLE – III Rated output
.
45 KW 55 KW 75 KW 90 KW 110 KW 125 KW 160 KW 180 KW 200 KW
Product of efficiency and power factor at rated load (minimum) 2-pole 4-pole 6-pole 0.82 0.80 0.79 0.82 0.80 0.79 0.82 0.80 0.80 0.82 0.80 0.80 0.86 0.80 0.80 0.86 0.80 0.80 0.86 0.81 0.80 0.86 0.83 0.80 0.86 0.83 0.80
E fficiency and power factor figures for motors having synchronous speed of 750 rpm and below shall be as agreed between the purchaser and manufacturer. 5.
GENERAL REQUIREMENT AND CONSTRUCTIONAL DETAILS
5.1
Windings a) Insulation and Bracing: Unless otherwise specified in the data sheet, motors shall be provided with “F” class insulation as minimum. The windings shall be tropicalised. The windings shall preferably be vacuum impregnated. Alternatively, the windings shall be suitably varnished, baked
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and treated with epoxy gel for operating satisfactorily in humid and corrosive atmosphere. Windings shall be adequately brazed to prevent any relative movement during operation and in this respect, particular care shall be taken for the stator winding of Direct-on-Line Starting Squirrel Cage Motor. Insulation shall be provided between coils of different phases which lie together. Core laminations must be capable of withstanding burnt out for rewind at 400 0C without damage or loosening. In case of motors driving equipments with pulsating loads, special attention shall be paid to the joints of the rotor bars and end rings to avoid premature failures due to induced fatigue stresses. b) Phase connections: The windings shall be connected in delta. However, for motors rated 2.2 and below, star connection may be accepted. If star-delta starting is required, this will be specified in data sheet and the motor windings shall be fully insulated for delta connections. c) Winding terminations: The ends of the windings shall be brought out in to a terminal box. They shall be terminated by means of terminal mounted on an insulating base made of non-hydroscopic and non-flammable material. All motors shall be with 6-terminals and suitable links to connect them in star or in delta. All terminals must be adequately designed. Line terminals shall be thoroughly insulated from the frame with material resistant to tracking. Anti-loosening, anti-vibration type terminals shall be provided in case of increased safety (type e) and non-sparking (type n) type of motors d) Terminal Box and Cable Entries Unless otherwise specified, the terminal box shall be located on the right hand side as viewed from the driving (coupling) end. It shall be ‘Rotatable’ in steps of 90 ° to allow cable entry from any direction. The terminal box shall be sturdy construction and large enough to facilitate easy connection of the cables. Terminal box cover shall be provided with handles to facilitate easy removal. An adequately sized earth terminal shall be provided in the motor terminal box for termination of the fourth core of specified cables. The terminal box shall be provided with cables lugs and entries for suitable cable glands corresponding to the number and size of specified
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cable. Nickel plated brass (or aluminium if specifically required) double compression type cable glands shall be supplied along with the motor for mentioned cable sizes or polyamide cable gland for motors below 5.5 KW. Equipment and accessories provided shall conform to the hazardous area classification and environmental conditions wherever required as specified in the motor data sheet. Unless otherwise specified the terminals, cable lugs, terminal box, cable entries and cable glands shall be suitable for the cables sizes as specified below for 2 pole 4 pole or 6 pole motors. Motor rating upto and including (mm²)
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Size of Phase Conductor
2.2 KW and below
4 Al. / 2.5 cu
3.7 KW
6 Al. / 4.0 cu
5.5 KW
10 Al. / 6.0 cu
7.5 KW
10 Al. / 6.0 cu
9.3 KW
16 Al. /10.0 cu
11.0 KW
16 Al. /10.0 cu
15.0 KW
25 Al. /16.0 cu
18.5 KW
35 Al / 25.0 cu
22.0 KW
35 Al / 25.0 cu
30.0 KW
50 Al / 35.0 cu
37.0 KW
70 Al / 50.0 cu
45.0 KW
95 Al / 70.0 cu
55.0 KW
120 Al / 95.0 cu
75.0 KW
185 Al / 2 x 70 cu
90.0 KW
2 x 95 Al / 2 x 70 cu
110.0 KW
2 x 120 Al / 2 x 95 cu
125 KW /132 KW
2 x 150 Al / 3 x 70 cu
160.0 KW
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180.0 KW
2 x 240 Al / 3 x 120 cu
200.0 KW
2 x 300 Al / 3 150 cu
NOTE: Cable sizes for motor having synchronous speeds 750 rpm and below shall be as agreed between the purchasers as manufacturer. Cable type Cables used are of 650/1100 V grade Aluminium conductor, PVC insulated, PVC extruded inner sheath, armored with overall PVC sheath for conductor crosssections of 35 mm² & above. However for cable upto & including 16 mm² crosssection cables used may be with copper or aluminium conductor as indicated in the data sheet. The terminal box shall be capable of withstanding internal short circuit conditions without danger to personnel or plant from the emission of hot gases or flame or due to excessive distortion or damage to the terminal enclosure. e) Phase Marking Appropriate phase markings as per IS-4728 shall be provided inside the terminal box. The marking shall be non-removable and indelible. 5.2
Motor Casing Type of Enclosure Motor for use safe areas shall be normal industrial type meeting the specified ambient conditions and operating requirements. The minimum degree of motor enclosures including terminal boxes and bearing housing shall be IP-55 as per IS: 4691. Motor for use in hazardous areas (Zone 1 or Zone 2) shall have type of protection Ex (d) or Ex (e) or Ex (n) as specified in the data sheet and shall meet the requirements of applicable Indian Standards. Ex (d) type of motors shall have a BIS marking on the name plate. Motor for outdoor use shall be suitable for installation and satisfactory operation without any protective shelter or canopy. Motor casing shall be provided with a suitable drain for removal or condensed moisture except in case of flameproof motors. Vertical motors with downward shaft shall be provided with fully covering rain canopies. Vertical motors with upward shaft e.g. on fin fan coolers, shall be adequately protected, (such as cowls/canopies) against ingress of water into the enclosure or the bearing house even when standing still for long periods of time. Motors designed to handle external thrust from the pump shall be supplied with a thrust bearing at the non-driving end. All internal and external metallic parts which may come into contract with cooling air shall be of corrosion resistant material or appropriately treated to resist the corrosive agents which may be present in the
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atmosphere. Screws and bolts shall be hot dip galvanized or zinc passivated to protect against corrosion. Unless otherwise agreed, motors shall have standard frame size for various output ratings as stipulated in IS: 1231 5.3
Bearing and Lubrication Motors shall have greased lubricated ball or roller bearings. In all cases, the bearings shall be chosen to provide a minimum L-10 rating of 5 years (40000 hours) at rated operating conditions (The L-10 rating life is the number of hours at constant speed that 90% of a group of identical bearings will complete or exceed before the first evidence of failure). Unless otherwise specified the bearing shall be adequate to absorb axial thrust produced by the motor itself or due to shaft expansion. Vertical motors shall be provided with thrust bearings suitable for the load imposed by the driven equipment. In cases such as pumps for hot liquids where the driven machine operates at high temperatures, bearings shall be cooled by shaft mounted fan. This shall be ensure efficient ventilation of the bearing and disperse the heat transmitted from the driven object by conduction or convection. For motors operating in hazardous areas fans shall be of an anti-static non sparking material. Bearings shall be capable of grease injection from outside without removal of covers with motors in the running conditions. The bearing boxes shall be provided with necessary features to prevent loss of grease or entry of dust or moisture e.g. labyrinth seal. Where grease nipples are provided, these shall be associated where necessary, with appropriately located relief devices which ensure passage of grease through the bearing. Pre-lubricated sealed bearings may be considered provided a full guarantee is given for 4 to 5 years of trouble-free service without the necessary of re-lubrication.
5.4
Cooling System All motors shall be self ventilated, fan cooled. Fans shall be corrosion resistant or appropriately protected. They shall be suitable for motor rotation in either direction without affecting the performance of the motor. If this is not possible for large outputs, it shall be possible or reverse the fan without affecting the balancing of the motor.
5.5
Rotor The rotor shall be squirrel cage type, dynamically balanced to provide a low vibration level and long service life for the bearings. The accepted values of peak to peak vibration amplitudes for a motor at rated voltage and speed on a machined surface bedplate with the motor leveled and with a half -key or coupling fitted shall not exceed those given in IS12075. Die cast aluminium rotors for motors in hazardous areas may be accepted provided the same are type tested and approved by competent authorities.
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5.6
Shaft Extension Motors shall be provided with single shaft extension with key. Motor shaft shall be sized to withstand 10 times the rated design torque.
5.7
Lifting Hook All motors except for fractional horse power motors shall be provided with lifting hooks of adequate capacity.
5.8
Earth Terminals Two earth terminals located preferably on diametrically opposite points shall be provided for each motor. Unless otherwise specified, the size of each earth stud shall be as given below: Motor Rating
Stud size
Upto and including 3.7 KW 5.5 KW to 30 KW Above 37 KW
6 mm 10 mm 12 mm
Necessary nuts and spring washers shall be provided for earth connection. An additional earth terminal shall be provided inside the terminal box stated in 5.1 6.
MISCELLANEOUS ACCESSORIES
6.1
Anti - Condensation Heaters All motors rated above 30 KW shall be provided with 240 V AC anticondensation heaters, sized and located so as to prevent condensation of moisture during shut-down periods. Motors rated 30 KW below shall be provided with anti-condensation heaters if specified in the requisition. Motors meant for humid location such as cooling tower fans, sump pump motors etc. shall be provided with space heaters irrespective of the motor rating in the motor data sheet. The heaters shall permanently remain 'ON' when the motor is not in service and as such shall not cause damage to the windings. The heater leads shall be brought out to a separate terminal box of the same specification and grade of protection as the main power terminal box excepting that the cable glands provided shall be suitable for two core 4 sq. mm aluminium conductor, armoured cable or 3 x 2.5 sq mm copper conductor armoured cable. A warning label with indelible red inscription shall be provided on the motor to indicate that the power line and the heater supply shall be isolated before carrying out any work on the motor.
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Name Plates A stainless steel name plate manufactured from series 300 stainless steel and as required under specification IS-325 shall be provided on each motor. In addition to the motor rating plate a separate motor plant equipment number plate shall be fixed in a readily visible position. This number shall be indicated in the data sheets attached with purchase requisition. Additional information as stipulated in applicable Indian standards shall be included in the name plate for motors meant for use in hazardous atmospheres as per IS: 13408.
7.
NOISE LEVEL The permissible noise level shall not exceed the stipulation laid down in IS- 12065.
8.
MOTOR VIBRATIONS Motor vibrations shall be within the limits of IS-12075 unless otherwise specified for the driven equipment.
9.
CRITICAL SPEEDS The first actual critical speed of stiff rotors shall not be lower than 125 % of the synchronous speed. For flexible rotors this shall be between 60% and 80% of the synchronous speed, the second actual critical speed shall be above 125 % of the synchronous speed.
10.
PAINTING Internal and external parts of the casing and all metal parts likely to come in contact with the surrounding air shall be protected with antiacid paint that will resist the particular ambient condition. All external surfaces shall be given a coat of epoxy based paint.
11.
INSPECTION AND TESTING The vendor shall allow purchase or his authorized representative to visit the works during manufacture of motors to assess the progress of work as well as to ascertain that only quality raw material is used for the same. He shall be given all assistance to carry out the inspection. The vendor shall given at least 4 weeks advance notice to the purchase, regarding the date of testing to enable him or his representative to witness the tests. The motors shall be tested in accordance with IS: 325 and IS: 4029. Type tests including any specification test to ascertain compliance with these specifications shall be carried out on one sample from each KW rating and frame size. Routine tests shall be carried out on all motors. In
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addition measurement of vibration and noise level (if desired) shall form a part of route tests. Tests on completely assembled motor shall be carried out in the presence of purchaser or his representative. The result shall be tabulated and signed by both vendor and purchaser or their representatives. Though the motors shall be accepted on the basis of the satisfactory result of the tests at the works, it shall not absolve the vendor from liability regarding the proper functioning of motor coupled to the driven equipment at site. 12. 12.1
DRAWING AND DATA Following minimum information shall be furnished along with the Bid: a)
KW Rating, Make, Frame Size, Full Load Speed, Mounting, Enclosure type and specific type of construction {Ex (D), EX (n)}.
b)
For heavy duty drives starting torque, starting time and lock rotor withstand time of the motor shall also be furnished.
12.2
After placement of order, vendor shall furnish all necessary data/ drawings/ documents including but not limited to the following: a) b) c)
d) e)
Completed Motor Data Sheet GA Dimension and Mounting details. Details of Terminal Box and Auxiliaries. Performance characteristics viz. Speed v/s Current and Speed v/s Torque. Thermal withstands curves under hot and cold conditions. Subsequent to completion of satisfactory inspection and testing, duly signed test certificates installation operation and maintenance manual shall be furnished by the vendor to complete the contractual obligation.
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AC VARIABLE FREQUENCY DRIVE AS PER THE FOLLOWING SECIFICATIONS. TECHNICAL SPECIFICATIONS: PLEASE REFER TO THE ANNEXURE ATTACHED ALONG WITH THE SPECIFICATIONS. RATINGS: KW / HP: 25 % MORE THAN THE RATED KW OF THE MOTOR FOR WHICH IT IS REQUIRED. INPUT VOLT: 380-480 VAC INPUT FREQUENCY: 50 HZ + / - 5 % MAXIMUM CONTINUOUS CURRENT: MORE THAN THE RATED CURRENT OF THE MOTOR FOR WHICH IT IS REQUIRED. OVER LOAD CAPACITY: 150 % FOR 60 SECONDS 200 % FOR 03 SECONDS LANGUAGE: ENGLISH. IMPORTANT NOTES FOR THE BIDDERS: 1. ALL THE ABOVE SPECIFICATIONS BASED ON 50 DEGREE CENTIGRADE AMBIENT TEMPERATURE WITHOUT DERATING. 2. ENCLOSURE: IP 00 FOR VFD MODULE IF IT IS INSTALLED IN AC CONTROL ROOM. MINIMUM IP 20 IF INSTALLED OTHER THAN CONTROL ROOM. 3. EACH VFD SHALL BE SUPPLIED IN A STAND ALONG PANEL HAVING SINGLE DOOR, BOTH FRONT & REAR OPENING, IP 43 RITTAL ENCLOSURE IF INSATTLED IN AC CONTROL ROOM AND MINIMUM IP 55 RITTAL ENCLOSURE IF INSTALLED IN OTHER THAN AC CONTRL ROOM WITH PANEL AC AS REQUIRED DEPENDS ON APPLICATION, FLOOR MOUNTING, WITH FANS, FILTERS, DOOR LOCK AND HANDLE. MAKE: RITTAL. PRIOR APPROVAL SHALL BE TAKEN FROM NALCO FOR TYPE OF ENCLOSURE AND VFD. 4. THE POWER WIRING SHALL BE WITH APPROPRIATE SIZE OF FINE CORE STRANDED COPPER CONDUCTOR WITH APPROPRIATE SIZE LUGS. 5. ALL THE CONTROL WIRING SHALL BE WITH COPPER 1.5 SQ. MM. FLEXIBLE WIRE. 6. ALL THE INTERNAL WIRING SHALL BE AS PER THE SCHEME ENCLOSEED HEREWITH FOR REFERENCE. 7. THE DRIVE SHALL BE SUITABLE FOR VARIABLE AND CONSTANT TORQUE DEPENDS ON APPLICATION. 8. THE TRANSFORMER, INPUT CHOKE, OUTPUT CHOKE SHALL BE MOUNTED AT THE BACK OF THE PANEL. ALL THE ELECTRICALS LIKE CONTACTOR, MCB AND FUSE SHALL BE MOUNTED IN THE FRONT OF THE PANEL. 9. VFD SHALL BE MOUNTED IN THE FRONT OF THE PANEL. 10. THE VFD, CONTROL TRANSFORMER, INPUT CHOKE, OUTPUT CHOKE AND ALL ELECTRICALS LIKE MCCB, MCB, CONTACTOR AND FUSE SHALL BE MOUNTED ON A MOUNTING PLATE /DIN RAIL AND THEN IN THE PANEL FOR EASE OF MAINTENANCE. 11. ERECTION SUPERVISION & COMMISSIONING WILL BE DONE BY THE PARTY.
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12. ALL THE TERMINAL BLOCK SHALL BE OF PHOENIX MAKE, TYPE: UK6N & NUMBERED. 13. THE ENTIRE RELAY, MCB SHALL BE OF SCHNEIDER MAKE ONLY. 14. FINAL SCHEME OF THE DRAWING & HOOKING WITH EXISTING PLC FOR AUTOMATION WILL BE FINALISED AFTER DISCUSSION AND CONSULTATION WITH NALCO. 15. THE MATERIAL WILL BE INSPECTED BY ENGINEERS OF NALCO AT VENDORS SITE BEFORE DESPATCH. 16. GC / TC SHALL BE SUBMITTED BY THE PARTY 17. THE INSTALLATION WILL HAVE MOTOR CABLE LENGTH OF APPROXIMATELY 150 METER. THE VFD AND PANEL COMPONENTS SHALL BE DESIGNED ACCORDINGLY. 18. THE PANEL SHALL HAVE A SEPARATE TRANSFORMER FOR ILLUMINATION AND VENTILATION FAN SUPPLY. 19. THE PANEL WILL HAVE CFL BASED ILLUMINATION WITH DOOR INTERLOCK. 20. THE PANEL SHALL HAVE ONE MCCB FOR VFD OF APPROPRIATE RATING AS INCOMERS. 21. A BREAKING RESISTER, IF REQUIRED, OF SUITABLE RATING TO PROVIDE 150% BREAKING TORQUE WILL BE SUPPLIED SEPARATELY. 22. THE VFD SHALL HAVE INBUILT OR EXTERNAL BRAKE CHOPPER TO PROVIDE 150% BRAKING TORQUE. 23. THE PANEL SHALL HAVE AMMETER AND VOLTMETER TO MONITOR INPUT CURRENT AND VOLTAGE. 24. INDICATION LAMPS FOR DRIVE STATUS AND POWER STATUS TO BE PROVIDED. 25. PARTY SHALL SUBMIT FINAL AS BUILT GA AND SCHEMATIC DRAWINGS AFTER COMMISSIONING OF THE PANEL. 26. PARTY MUST SUBMIT THEIR COMPLETE TECHNICAL LITERATURE ALONG WITH THE OFFER FOR OUR TECHNICAL SCRUTINY. 27. IT IS MANDATORY FOR THE BIDDER TO CONFIRM EACH AND EVERY TECHNICAL DATA MENTIONED IN THE NIT FOR TECHNICAL SCRUTINY PURPOSE.
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ANNEXURE General Specification of Variable Frequency Drive Reference: IEC 146 International Electrical Code Regulatory Requirement: IEC 801 Product Rating: Input Power: The Drive shall be self adjustable to accept an input voltage range between 380-480 VAC, 3-Phase ± 10 %. Frequency Range shall be 50 Hz ± 6%. Displacement Power Factor shall range between 1.0 and 0.95, lagging, over the entire speed range of drives. The efficiency of the drive shall be minimum of 97.5 % at full load and speed. Environment: Storage ambient temperature range: (-) 40 to (+)70 Degree Centigrade (-40 to 158 F). Operating ambient temperature range should be 0 to 50 Degree Centigrade (0 to 109 F). The relative humidity range should be 5 % to 95 % non-condensing. Operating elevation: Upto 1000 meters (3,300 ft) without derating. Out Power: The output voltage should be adjustable from 0 to rated input voltage. The output frequency range should be adjustable from 0 to 400 Hz. The inverter section shall produce a pulse width modulated (PWM) waveform using latest generation IGBTs. Hardware: The drive hardware should employ the following power components. • Diode or fully gated bridge on the input. • Phase to Phase and Phase to Ground voltage surge protection. • Gold plated plug-in connections on printed circuit boards. • Microprocessor based inverter logic isolated from power circuits. • Protection against input voltage dips and swells.
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• Latest generation IGBT inverter section. • Inverter section shall not require commutation capacitors. • Peripheral Interface to enable attaching common options.
Control Logic: The drive should be programmable or self adjusting for operation under the following conditions. • Operate drive with motor disconnected. • Controlled shut down, when properly fused, with no component failure in the event of an output phase to phase or phase to ground short circuit and annunciation of the fault condition. • Adjustable PWM carrier frequency within a range of 2-8 KHz. • Selectable Sensor less Vector or V/Hz mode. • 250 % Starting Torque and 260 % Peak Torque. • Selectable for Variable or Constant Torque Loads. Selection of variable torque provides 115 % of rated VT current for up to one minute. Selection of constant torque provides 150 % of rated CT current for up to one minute. • Multiple programmable stop modes including- Ramp, Coast, DC- Brake, Ramp-to-Hold and S-Curve. • Multiple acceleration and deceleration rates. • All adjustment to be made with the door closed. • Adjustable output frequency up to 400 Hz. Power Conditioning: The Drive shall be designed to operate on an AC line which may contain line notching and up to 10 % harmonic distortion. An input isolation transformer shall not be required for protection from normal line transients. If the conditions dictate the use of a transformer, the K factor shall be 4 or less. Operator Interface: Interface to the drive is to be provided via a removable Human Interface Module with integral display. The display should be 2 lines, 16 characters alphanumeric, backlit LCD used to show drive operating conditions, fault indications and programming information. The display should also be configurable for
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simultaneously displaying two values using customized multi-lingual text and user scaled units. Reference Signals: The drive shall be capable of the following input reference signals: • Digital Pulse Train Input • HIM(Program/Control Panel) • Analog Input Signals as Remote Potentiometer 0 to 10 VDC 0 to 20 mA • Digital MOP • Serial The analog inputs shall have programmable gain adjustments for both upper and lower settings to allow for system calibration. The analog inputs shall be programmable for normal, inverted or square root operation.
Loss of Reference: The drive should be capable of sensing the following reference loss conditions. • Remote potentiometer wiper loss. • 2-10 V DC signals below 2 Volts. • 4 to 20 mA signals below 4 mA. In the event of loss of an analog input reference signal, the drive should be user programmable for one of the following conditions. • • • • •
Fault and Stop. Alarm and maintain last reference within 10 %. Alarm and go to the preset speed. Alarm and go to the minimum speed. Alarm and go to the maximum speed.
Signal loss detection should also be available when the signal being monitored is • The active Process PI reference or feedback. • The active Frequency reference.
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Digital I/O: Digital I/O shall consist of seven inputs, accessible through input cards and two Form A and two Form C relay outputs as standards. Digital Inputs: Out of seven Digital Inputs, 6 should be freely programmable for any fixed function that includes external fault, Speed select, Jog, Process PI functions, Second Acceleration /Deceleration, Stop Type and others. Digital Outputs: Standards “On Board” Digital outputs shall include two Form A (1 N.O.) and two Form C (1 N.O. - 1 N.C.) out put relays. Contact output ratings should be 240 VAC. All four relays provided should be programmable to different conditions including Fault, Alarm, At Speed, Drive Ready, Pl Excess Error and others. Features: Start Up Mode: An Assisted Start-Up Feature should be available for the user to commission the drive by supplying basic information and answering simple Yes/No questions. Basic setup parameters shall include Minimum and Maximum Frequency, acceleration and deceleration times and other can conveniently entered. Motor nameplate data, Encoder information and I/O setup shall also be included in the assisted start up. A motor rotation test and automated sensor less vector tuning also should be possible in simple assisted startup. A full manual start up should also be possible. Control Mode: The ability to select sensor less vector or V/Hz mode should be available through programming. The sensor less vector mode should use motor nameplate data plus motor operating data such as IR drop, nominal flux current and flux up time to adapt to various
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operating conditions. The volts per hertz mode shall be fully programmable for fixed boost or full custom patterns. Current Limit: Programmable current limit from 20 % to 160 % of constant torque rating shall be provided. Current limit should be active for all the drive states, accelerating, constant speed and decelerating. The current limit parameter shall also be externally controlled through Analog Input. Acceleration/Deceleration: Acceleration/Deceleration setting should provide separate adjustments to allow either setting to be adjusted from 0.0 seconds to 3600.0 seconds. A second set of remotely selectable Acceleration/ Deceleration setting should be accessible with Control Interface option. An adaptive current limit circuit should be available to allow enabling for high Inertia and Disable the programming for fast acceleration of low inertia loads. Speed Regulation: The programmable speed regulation modes shall include the following. • Open Loop. • Slip Compensation with 0.5 % speed regulation. • Droop-Negative Slip Compensation with 0.5 % speed regulation. • Traverse Function. • Closed Loop encoder feedback with 0.1 % speed regulation. • Process PI Control. • Speed range should be 120:1 or better to get good Torque at low speed. Speed Profiles: Programming capability to produce speed profiles with linear acceleration/ deceleration or S-Curve profiles that provide changing acceleration/deceleration rates shall be available. SCurve profiles shall be selectable for fixed or adjustable values.
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Bus Regulation: DC Bus regulation shall be available to reduce the possibility of drive Over Voltage trips due to regenerative. Bus regulation shall be enabled or disabled via programming. Skip Frequency: Three adjustable set points that lockout continues operation at frequencies which may produce mechanical resonance shall be provided. This should have a bandwidth adjustable from 0 Hz to 15 Hz. Run on Power Up: A user programmable restart function should be provided to automatically restart the equipments after restoration of power after an outage. Fault Memory: Last four faults as well as operating frequency, drive status and power mode should be stored at the time of fault. Information should be maintained in the event of power loss. Auto Economizer: This feature should automatically reduce the output voltage when the drive is operating in an idle mode (Drive output current less than programmed motor FLA). The Voltage should be reduced to minimize flux current in a lightly loaded motor thus reducing KW usage. If the load increases, the drive should automatically return to normal operation. Flying Start: The drive should be capable of determining the speed and direction of a spinning motor and adjusts its output to “Pick-Up” the motor at the rotating speed. The flying start feature should be operable with or without encoder feedback. Adjustments:
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The digital interface should be used for all set-up, operation and adjustment settings. All adjustments should be stored in nonvolatile memory (EPROM). No potentiometer adjustments are permitted. Protection: Following protection should be inbuilt into the drives: Ground Fault, Short Circuit each Phase, Drive Over Current, At temperature, Over Temperature, Under Voltage, Over Voltage, External Signal Loss, Analog Signal Loss etc.
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STANDARD ELECTRICAL SPECIFICATION FOR OFFSIDE PACKAGE UNITS
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CONTENTS 1. SCOPE 2. CODE AND STANDARDS 3. SITE CONDITIONS 4. AREA CLASSIFICATIONS AND EQUIPMENT SELECTION 5. POWER SYSTEM DESIGN 6. EQUIPMENT SPECIFICATIONS 7. CABLING SYSTEM 8. LIGHTING SYSTEM 9. EARTHING SYSTEM 10. INPECTION, TESTING AND COMMISSIONING 11. SPARES 12. DRAWINGS AND DOCUMENTS
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1. SCOPE This specification along with specific jobs requirement if any defines the requirements for design, engineering, procurement, testing and commissioning of electrical facilities for the package unit as covered in the enclosed data sheet. It is not intended to cover all aspect of system design but to indicate the basic requirement only. Vendor shall ensure that the design and installation is carried out as per the good engineering practice and shall meet the requirement of safety, reliability, ease of maintenance and operation aesthetics scope of further expansion and maximum interchangeability of the equipments. Vendor shall acquaint themselves with Nalco Standards, Specifications and Field testing procedure as deemed necessary for proper execution of the work. Compliance with this specification and / or review of any of the vendor documents shall not relieve the vendor of his responsibility towards his contractual obligation with regards to the completeness and satisfactory operation of the plant. 2. CODES AND STANDARDS All electrical equipments and complete installation shall meet the requirements of this specification and data sheet in addition to the relevant Indian Standards, Code of Practice, Nalco Standards, Statutory Regulations and Sound Engineering Practice. Complete system must also confirm to the latest revision of following. a. Indian Electricity Act and Rules b. Fire Insurance Regulations c. Indian Petroleum Rules and any other regulation lay down by chief Controller of Explosives. d. Regulation laid down by Factory inspectorate e. Regulations lay down by local statutory authorities and electrical inspector. f. The Factory Act g. Oil Mines Regulations (For Project under DGMS jurisdictions). Approvals of statutory authorities for materials, Plant, design, drawing and complete installation shall be the responsibility of the vendor. Where Indian Standards do not exist, the relevant IEC, British or German (VDE) Standards shall apply. Any other standards may also be followed provided it is equivalent to or more stringent than the standard specified above.
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In case of any deviation conflict of these specifications with the codes and standards the following order of precedence shall be govern. I. Statutory Regulation II. Job Specification and Equivalent data Sheet III. Nalco Standard Specification, Installation Standards etc. IV. Codes and Standards Owner concurrence shall however be sought before taking a decision in this matter. 3. SITE CONDITIONS The equipment and installation shall be suitable for continuous operation under the site conditions as specified in the enclosed data sheets. If not specifically mentioned a maximum ambient temperature of 50 º C and altitude not exceeding 1000 meters above mean sea level shall be taken in to consideration. 4. AREA CLASSIFICATION AND EQUIPMENT SELECTION In case of storage, handling or processing of flammable material within the battery limits of the package unit area classification shall be carried out in line with IS: 5572, Petroleum rule and DGMS guidelines as applicable. The vendor shall furnish ‘Area Classification Drawing’ indicating the zone of hazardous area and the gas group. A list of flammable material handled along with their properties like flash point, ignition temperature, explosive limits etc. shall also be furnished by the vendor. All the electrical equipment installed in hazardous area shall be selected as per IS: 5571 and DGMS regulations, where applicable and shall meet the requirements of relevant IS, IEC or NEC Standards. However, electrical equipment for Zone-2 area as minimum be Ex ‘e’, Ex ‘n’, type as per IS, IEC Codes subject to the same being acceptable to the concerned statutory authorities. Increased safety (type Ex ‘e’) equipments shall not be used in Zone-1 areas. Electrical equipments of hazardous area shall be certified by recognized testing authorities and shall have the approval of statutory authority. Vendor shall furnish the necessary certificate indicating such approval. All flame proof equipment shall carry the BIS marking. Electrical equipments for hazardous area shall generally be suitable for gas group IIA, IIB and Temperature Class T3 as applicable to the selected type of explosion protection. In case of hydrogen the gas group to be considered shall be IIC. All Electric Motors for Agitator’s Mixers and Metering Pumps handling flammable materials and Oil Sump Pump shall be flame poof type irrespective of the area being classified as Zone-2 or Zone-1.
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5. POWER SYSTEM DESIGN The distribution system shall be designed in accordance with project specifications/data sheets and shall ensure continuity of supply, flexibility, of operation, safety and reliability of supply. All the components of electrical system must be sized to suit the maximum load under the most severe operating conditions. Wherever envisaged, a separate emergency power supply system shall be provided for feeding loads essentials for the safe shut down of the plant, emergency lighting, DC supply and UPS system and load critical for process, plant and personnel safety. Capacity of Electric Plant All components of the Electrical System shall be sized to suit the maximum load under the most severe operating conditions. Accordingly, the maximum simultaneous consumption of power required by continuously operating loads shall be considered and additional margin shall be taken into account for intermittent service loads, if any. System Voltage and Frequency Voltage level for electrical distribution system and equipments utilization voltages shall be as per Project Specifications Data Sheets. System Frequency shall be 50 Hz. Voltage Drops Maximum voltage drops in various sections of the electrical system shall be within the following limits. Cables between MCC and Motors : 3 % Cables between auxiliary switch: 1 to 1.5 % Board/MCC and Lighting/ Power Panels • Cable between Lighting and Lighting Point: 4 % • •
For medium voltage motors, the voltage available at the motor terminals must not be less than 75 % of the rated value during start-up or reacceleration. The voltage drop during motor start-up/ reacceleration at the MV switch board shall be limited to 10 % of rated voltage.
Sub-Station/MCC Room Sub-Station or MCC Room, wherever required shall be located in a safe area close to load centre. The building shall be sized to take care of present and future
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needs and to maintain adequate clearance between equipments for ease of maintenance. Minimum clearance shall be as follows. Front clearance for all Switch Board Panels: 2000 mm Rear clearance for panels requiring : 1500 mm maintenance from rear • Side clearance between two Switch-Boards: 1500 mm or from nearest obstruction • Vertical clearance measured from Bottom of the roof slab: 1500 mm Bottom of the lowest roof beam: 500 mm • •
Battery bank shall be located in a separate adequately ventilated room along with necessary exhaust system and water connection with sink. Floor of the battery room and wall upto 1.0 Meter height shall have acid/alkali resistant protective material coating. Adequate safety equipment such as Rubber ,Mats, Exit Sign, Shock/Fire Hazard Charts, First Aid Box, Portable Fire Extinguisher etc. shall be provided in the Sub-Station /MCC Room as per statutory regulation. Switchgear Main Bus Bars shall have rating atleast equal to the maximum demand under any circuit configuration plus a provision for 20 % future growth. Incomers of these switch boards shall be design to cater to the complete load including 20 % margin for the future growth. Spare outgoing feeders shall be provided in all switch boards. At least one number of each rating and type or 20 % whichever is more shall be provided as spare. Motor Circuit Breakers shall have rating atleast 25 % above the maximum continuous rating of the motors. Separate Feeders shall be provided in the switch board for each Load/Motor. However, as an exception maximum two numbers welding receptacles may be connected to one power feeder. All incomers to same switch boards shall be of equal rating. All circuit breakers shall be of single break type having one pole per phase. Each Short Circuit Interrupting Device shall be designated to have breaking capacity equal to or higher than the maximum value of the Short Circuit Current at the point of installation. MCCB’s with backup fuse shall not be acceptable. Air Circuit Breakers (ACB) shall be provided in MV Switchboards for all feeders rated above 400 A.
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Circuit Breakers /Switch Fuse Units for Capacitors shall have a current rating of atleast 135 % of the Capacitor rated current. Circuit Breakers capability to interrupt applicable capacitive current shall be specifically verified. The Switch Board components viz. Circuit Breakers, Main Horizontal and Vertical Busbars, Busbars Joint, Busbar Supports etc. shall be designed to withstand the maximum expected short circuit level for minimum 1 second. Moulded Case Circuit Breaker for power feeders shall have built in short and thermal overload releases. Moulded Case Circuit Breakers shall be of utilization category B and shall be rated for short-time withstand current as indicated in the enclosed data sheets. The rated service short-circuit breaking capacity of MCCBs shall be more than or equal to the specified fault level. For motor above 3.7 KW, CTs shall be provided in the switchgear for ammeter on the local push button station, unless otherwise specified. The Power Control Centre (PCC) generally include incomers, bus coupler, outgoing breaker feeders, large TPN Switch fuse feeders and motors feeders of rating as mentioned in project specifications/data sheets. The Motor Control Centre (MCC) shall generally include motor feeders of rating upto and including 55 KW unless otherwise specified in the project specifications. The maximum rating of busbar shall preferably be limited to 800 Amps. In case MCC having two incomers, necessary tie switch shall be provided bus sectionalizing. Heavy duty type Load Break Switches/ACB as specified in the data sheets shall be used for incoming and tie feeders and these shall have suitable interlocks and shall be designed to withstand the specified short circuit level for minimum 1 seconds. All motors starting shall be DOL type unless other wise specified. 6. EQUIPMENT SPECIFICATIONS Specifications of each system and equipment shall be furnished by the vendor for review by the owner. However, certain minimum requirements for the major equipments are highlighted in this section. All equipments shall be new and supplied by approved reputed manufacturers. Equipments requiring specialized maintenance or operation shall be avoided as far as possible and prototype equipments shall not be acceptable. All equipment shall be complete with all necessary weather and anticorrosion protection including tropicalization to prevent damage due to climate, saline atmosphere, dust and corrosive vapor. All equipment/material shall be protected for inland/marine transport, carriage at site and outdoor storage during transit and at site. Vendor shall be responsible for any damage to the equipments due during transit. All packages shall be clearly, legibly and durably marked with uniform block letters giving the relevant equipments/materials details. Such package shall contain a packing list in a water proof envelope.
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High Voltage Motors All high voltage motors shall be as per requirements given in the enclosed data sheets and Nalco’s standards specifications. Medium Voltage Motors All medium voltage induction motors shall meet the requirement of Nalco standard specifications and enclosed data sheets. Medium Voltage Switchboard and Bus Duct Medium Voltage Switchboard shall be in fixed drawout execution as specified in the data sheets and shall confirm to Nalco‘s standard specifications for drawout type switchboard and Nalco’s standard specifications for fixed type switch board. The switchboard shall also meet the requirements of enclosed data sheets in addition to the general requirements as per latest editions of applicable Indian Standards. Medium voltage bus-duct shall confirm to Nalco’s Standards Specifications. Bus-duct shall be design to withstand specified short circuit current for minimum 1 second. Proper sealing arrangements shall be provided at the wall when bus-duct enters the switchgear room. Local Control Station Each motor shall be provided with a pedestal mounted control station in the field near the motor. The local control station shall have die-cast aluminium sheet steel enclosure of IP-55 protection category and shall be flameproof type with cast aluminium alloy LM-6 enclosure for installation in hazardous area. The control station shall include START/STOP push buttons or Breaker Switch, Cable glands, Ammeter, Auto/Manual Selector Switch etc. as required. STOP Push buttons shall generally stay put feature except in the case of critical drives such as lube oil pump etc. All push buttons shall be shrouded type. Rear connected with 2 NO + 2 NC momentary contact and shall be complete with necessary inscription plate. Out door control station shall have necessary canopies. Motor installed at elevated platform (such as cooling tower fan, air fan cooler etc.) shall be provided with a Stop Push Button at ground level in addition to one near motor. Welding Receptacles The welding receptacle shall be industrial heavy duty type rated for 415 VAC, 60 Amperes, three phase system, complete with scraping earthing facilities, necessary interlock and insulated plug. The receptacles shall be weather proof type and additionally suitable hazardous area.
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Adequate number of welding receptacles shall be provided at suitable locations to ensure accessibility with 50 meter length of trailing cable to any point within battery limit of the package unit. Hazardous Area Lighting Fixture and Accessories Lighting Fixture and Accessories for installation in hazardous area shall be suitable for zone-1 or Zone-2 area as require, gas group IIA/IIB and Temperature Class ‘T3’ unless specified otherwise. The material of construction of the enclosure shall be cast Aluminium alloy LM-6. All equipment shall be suitable for outdoor installation with IP-55 degree of protection and shall confirm to Nalco’s Standard specifications. 7. CABLING SYSTEM Power cables for use in 415 VAC system shall be of 1100 V grade Aluminium/Copper conductor. PVC Insulated, PVC Sheath, Armoured with overall PVC Sheath as per IS: 1554 (Part-1) unless otherwise specified. Power cables for conductor cross sections of 35 Sq. mm and above shall be with aluminium conductor. However cables below 35 sq. mm cross section shall be copper or aluminium conductor as specified in the data sheets. However, Power & Control Cables from Local Control Panel/LBS to Motor shall be of ‘Flexible, PVC Insulated Copper Cables’ only. Power cables for 3.3 kV / 6.6 kV / 11 kV systems shall be aluminium conductor, XLPE insulated, screened, PVC embedded, galvanized steel flat armoured and PVC sheathed as per IS: 7098 unless otherwise specified. Both inner and outer sheath shall be of extruded PVC for all power and control cables. Control cables shall be 660 V grade, 2.5 Sq. mm, solid copper conductor, PVC insulated, PVC Sheath, single wire armoured with an overall PVC sheath as per IS:1554(Part-1). 20 % of cores with minimum of one core shall be kept as spares. All cable shall be flame retardant type unless specified otherwise in the data sheet job specifications. Outer sheath of cables shall be black in colour and the minimum value of oxygen index shall be 29 at 27 ± 2 degree centigrade. In addition suitable chemical shall be added in to the PVC compound of the outer sheath to protect the cable against rodent and termite attack. The power and control cables shall have the following minimum sectional area. • • •
Medium Voltage Power: 4 Sq. mm Aluminium/ 2.5 sq. mm Copper Control Cables : 2.5 sq. mm Copper Lighting : 2.5 Sq. mm Copper
Cables shall be sized based on the maximum continuous load current and the voltage drop. The de-rating due to ambient air temperature, ground temperature, grouping and proximity of cables with each other etc. shall be taken into account. For project under DGMS jurisdictions all cables shall be heavy duty mining type with copper conductor.
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Cables shall be laid above or below grade as indicated in the project specifications. Cable for fire water system shall be taken on exclusive route through underground trench. Above ground cables shall be well supported on cable tray and suitably protected against mechanical damage. Routing shall be decided ton avoid interference with hot surfaces or places subject to undue fire risk. Above ground cables shall be preferably be laid in overhead cable trays along the pipe rack/pipe sleepers wherever available. Wherever pipes rack/ pipe sleepers are not available, cable shall be laid in above ground cable trays on separate sleepers/rack. Below grade cables in paved areas shall be in concrete lined trenches with concrete covers having proper slope and suitable drainage arrangement to avoid water collection. In unpaved area cables shall be in lined trenches or directly buried in ground as specified in the data sheets. In hazardous areas trenches shall be completely filled up with stand. Concrete lined cable trenches shall be sealed against ingress of liquid and gases wherever the trenches leaves a hazardous areas or enters control room or sub-stations. The cable trenches shall be sized depending upon the number and voltage grade of cables. Where underground cables cross road ways, pipe sleepers at grade etc. they shall be protected by being drawn through sleeves ducts to provide a permanent crossing. Pipes laid for mechanical protection shall be sealed at both ends. Cable tray racks and trenches shall be sized to allow for 20 % future cables. Cables installation shall provide minimum cable bending radius as recommended by cable manufacturer. Cable route marker shall be installed at every 30 Meter interval all along the cable routes and also at locations where the direction of cable trench changes. All cable trays and accessories shall be prefabricated, hot dip galvanized. The amount of galvanizing shall be minimum 610 gms./meter sq. Cable trays shall be supported at a distance not exceeding 2000 mm. Tray width shall be preferably 300/500/750 mm and shall be arranged in single/multi-tiers as required. All power and control cables shall be of continuous length without intermediate joints. All cables shall carry a cable tag number for easy identifications. In case of control cables all cores shall be identified at both ends by their terminal numbers using PVC ferules as per interconnection diagram. All PVC cables upto 1.1 kV grade shall be terminated by means of double compression type glands or Polyamide glands of reputed make and tined copper crimping type of lugs. All cable entries shall be through bottom only unless otherwise approved. 8. LIGHTING SYSTEM
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Wherever lighting is included, design of lighting system shall be included in vendor’s scope. The design shall include lighting calculations, layout, cabling and wiring size etc. Lighting system shall consist of lighting distribution board/ panels, fixture, junction boxes, 3 pin 5 A/15 Amperes convenience socket outlets cable glands etc. all conforming to the required area classification and environmental conditions. Illumination level shall not be less than the levels mentioned below the specific areas. • • • • • • • • •
Control Room & In-front of Panel : 500 Lux Behind Panel : 300 Lux Office : 300 Lux Switch Gear Room : 150-200 Lux General Process Area : 60 Lux Compressor Area : 150 Lux Pump House, Sheds : 100 Lux Loading Area and Staircase : 60 Lux Road and Tanks Farm : 10 Lux
A maintenance factor of 0.7 shall be assumed for lighting illumination level calculations for normal areas. Co-efficient of utilization shall be calculated as per fixture type and areas. It shall be vendor’s responsibility to demonstrate the illumination levels as indicated above using lux-meter. If the levels are found to be below the specified values. The vendor shall provide additional lighting fixtures and install them in uniformity. Dark patches and uneven illumination shall be avoided. The lighting system shall cover normal/emergency lighting designed for 415 to 240 VAC three phase four wire system (except in case of projects under DGMS jurisdiction where it shall be 240V three phase three wires) and critical lighting designed for 110V/ 220V DC system as per data sheet. HPMV lamps shall generally be used for outdoor plant lighting. Necessary incandescent lamps may be judiciously distributed throughout the plant area to avoid complete darkness in case of voltage dip/brown out condition. Fluorescent lamps may be used for indoor lighting for nonprocess buildings and control room. Safe area street lighting may employ sodium vapor lamps. All chemical handling facilities shall be provided with chemical resistant fixtures. Low pressure sodium vapor lamps shall not be installed in hazardous areas. DC critical lighting shall employ incandescent lamps. All ballasts shall be with copper winding and capacitor for power factor improvement (to 0.95) shall be provided with fixtures as applicable. Tall structures shall have aviation obstruction lighting as per statutory requirements. All lighting fixtures shall be supplied complete with control gear and lamps special fixtures, wherever required to meet operational requirements. Aesthetics etc. shall also be provided by the vendor.
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Lighting wiring between panels and lighting fixtures shall be done by PVC insulated core phase. Neutral and Earth armoured cables except building which shall through concealed conduit. All lighting cables shall be 3X2.5 mm 660/1100v grade Copper Conductor, PVC insulated armoured type. Concealed conduit wiring shall be done in 25 mm diameter minimum 16 gauge black enameled steel conduit. All lighting fittings/ convenience outlets shall be earthed through the third wire/ separate core in conduit/ cable. On Walkway, Platforms and other outdoor areas, Lighting fixtures shall be nearer to landing of Stairs or Ladders, Gauges, Flow meters, Panel Boards and other equipment requiring good illumination. In pump and compressor areas and other locations at ground level, Lighting Fixtures shall be mounted preferably 4 meters above floor level. Where this is impracticable, the minimum height of any lighting fixture shall not be less than 2.5 meters. Socket outlets in process areas shall be approximately 1200 mm above grade and 300 mm above grade in office area. Lighting power panels shall be mounted such that the top of the panel is 1800mm above finished grade. Control gears of light fixtures with separate control gear shall be mounted at suitable height from ground/platform for easy access for maintenance. In addition to the normal lighting system, Emergency Lighting shall be provided to allow for personnel safety, plant operation and safe shutdown during normal lighting system failure. Emergency lighting system shall be fed from a separate emergency lighting panel. Generally 20-25% of total lighting fixtures shall be fed from AC emergency supply. Critical lighting shall be provided for emergency escape routes, such as Sub-Station, Control Rooms etc. and strategic locations where specific safety/shutdown operation are to be carried out. Where DC supply is not available, emergency lighting units fed by a self contained battery and charger operating on 240 V supply shall be provided. All lighting circuits and convenience receptacles shall be fed from lighting power panels. Where large number of lighting power panels are required independent Main Lighting Distribution Board/ Lighting Distribution Board (MLDB /LDB) with energy metering facility shall be provided. MDB /LDB shall be dust and vermin proof floor mounting type with 14 SWG sheet steel. MDB /LDBs shall have sufficient space between gland plate and terminals for easy termination and dressing of cables. Lighting and power panel shall be fed from LDB/MDB 415/415 Dyn11 dry type lighting transformer having ±5 % in steps of 2.5 % wherever included in the scope of work. In case of mines installation secondary side voltage shall be 240 VAC between phases. Lighting and power panel shall be provided with Isolator and ELCB as incomer and Miniature Circuit Breaker (MCBs) for control and protection of lighting circuits. Two pole MCBs shall be used for controlling lighting circuit in hazardous areas. Power and lighting panels shall be of 14 gauge sheet steel constructions and shall be suitable for surface or flush mounting. A hinged door to cover the operations knobs shall be provided.
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These panels shall be flush mounting in the building with operating Knobs projecting out. Outdoor panels shall be housed in outdoor weather protected KIOSK with IP-55 protection. All outdoor lighting shall be automatically controlled by means of photoelectric cell or synchronous timers as specified in the data sheet with manual overriding control. If not specifically mentioned therein synchronous timers shall be used for control of outdoor lighting. Normally about 8-10 fixtures shall wired in each circuit. Lighting feeders requiring automatic control shall be provided with contactors of suitable rating. Sufficient numbers of 5 A and 15 A receptacles shall be provided with the battery limits so that any point is accessible to a 15 A receptacle with a 15 M long wire/cord. In hazardous area associated 240/24 VAC transformer and 24 V flame proof hand lamps shall be provided. Adequate number of ceiling fans shall be provided allocated for operating and maintenance personnel ceiling fans are provided, lighting fixtures shall be level with the help of conduit/chains to avoid shadow
in offices and rooms etc. In places where suspended below fan on the floor.
Switches for control of lighting/exhaust fan in battery room, shall be provided outside the room. Minimum of two exhaust fans shall be provided in the battery room and light fittings shall be mounted on the walls. 9. EARTHING SYSTEM Earthing system design and installation shall generally be as per IS: 3043. All metallic non current carrying parts of electrical apparatus, current and potential transformer secondaries, structural steel, vessels, towers, stack, storage tank, loading racks etc shall be earthed atleast by two distinct separate earth conductors from the plate connected to the main earthing loop. The main grid conductor shall be hot dip galvanized MS flat or PVC insulated aluminium/ copper conductor of suitable size. The amount of galvanizing shall be minimum 700 gm per sq. meter. The main earth loop shall be laid at a depth of 500 mm below grade level. Earthing conductor shall be laid around the package unit area. Horizontal conductors shall be laid in both longitudinal and transverse direction to facilitate the earthing of various equipments in most economical and reliable manner. The cable trays in offsite/utility/process areas shall be earthed at an interval of approximate 30 meters with the help of risers emerging from main earthing conductors laid below/adjacent to structures carrying cable tray. Joints and tapping in the main loop shall be made in such a way that reliable and good electrical connections are permanently ensured. All joints below grade shall be welded and suitably protected by giving two coats of bitumen
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and covered with Hessian tape. Tee connectors shall be used for tapping earth leads from the main earth loop wherever installed above ground. Adequate number of 65 mm diameter, 3 meter long GI pipe earth electrodes shall be provided with main loop to limit the earth resistance of the package unit earth grid to a value that ensure the operation of the protective devices but is not more than five ohm. All earth electrodes shall preferably be driven to a sufficient depth to reach permanently moist coil. Package unit earth grid shall have provisions for interconnection to owner’s main plant earth grid. Multiple earth connection shall be taken from suitably located earth plates. Spring washers shall be used for all earthing connections of equipment. Following sizes of earth conductors shall be used for motors. Upto 3.7 KW 5.5 to 30 KW Above 37 KW
: 8 SWG G1 wire : 3/8 inch GI fine wire rope or 35 sq. mm Aluminium insulated Conductor. : 5/8 inch GI fine wire rope or 70 sq. mm Aluminium insulatedConductor
Earthing connections to equipments shall be made by means of specially provided bolts and lugs. Lighting protection shall be provided for Equipments, Structures & Buildings. Self conducting structures may not be provided with aerial rod and down conductors but shall be connected to the earthing grid at minimum two points of the base. An independent earthing network shall be provided for lighting protection and this shall be bonded with the main earthing network minimum at two points at the buried electrodes. All utility, process pipelines shall be bonded and earthed on entering/ leaving any hazardous area. In addition, bonding shall be provided across all pipelines flanges.
INSPECTION TESTING AND COMMISSIONING All the equipments shall be tested and inspected at vendor’s works before dispatch to ensure compliance with the latest relevant specifications of Bureau of Indian Standards and agreed quality assurance/testing plan. The owner or his authorized representatives may visit the works during manufacture of various electrical equipment/materials to assess the progress of work as well as to ascertain that only quality raw materials are used for the same. He shall be given full assurance to carry out inspection. Owner’s representatives shall be given minimum two weeks advance notice for witnessing the final testing. Minimum testing inspection requirements for all components equipments shall confirm to the requirements stipulated in applicable codes and
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standards. Test certificates including test records and performance curves etc. shall be furnished by the vendor. Vendor shall submit the field testing procedures for owner’s approval. Field tests as per the approved procedures/ procedures available with Engineer-inCharge or his authorized representative shall be performed on the electrical system, equipment before its being put into service. All test equipment shall be arranged by the vendor. Test reports shall be approved by the Site-inCharge before acceptance of the complete plant and equipment. SPARES Vendor shall submit list spares and consumables required for operation and maintenance for minimum two years of the complete and associated equipment in addition to those required during field and commissioning. These spares shall include but not be limited following.
proper system testing to the
H.V.MOTOR • Driving end and driving end bearings • Terminal block • Terminal cover with screws etc. • External cooling fan M.V.MOTOR • Driving end and non driving end bearings • Terminal block • Terminal cover with screws etc. • Fans for critical motors. MEDIUM VOLTAGE SWITCHBOARDS • Spares for the breaker • Switches and fuses of all ratings • Set of main contacts and coils of all contactors • Bimetal relays of critical ratings • Indicating lamps DRAWINGS AND DOCUMENTS As built documents vendor drawings shall be provided by the vendor to owner as per contract. Additionally one set of all as –built documents/ vendor drawings in bound volumes and/or in the form of electronic files on specified media shall be submitted to NALCO Chief Manager alongwith certified and updated drawings schedule. In addition to as built drawings, vendor shall provide the following documents relevant to the supplied equipment as required for Operation, Maintenance and staff training.
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a) Design and installation instruction manual including design documents. Certificates relating to type/acceptance/special tests. Description of procedures and description of field testing procedures after installation. b) Operating instruction including description of start-up procedure and description of conditions of use. c) Maintenance instructions including preventive maintenance instructions/ periodic inspection programmes. Instructions / procedures for removing and replacing all parts/accessories included in the spare parts list and list of spare parts and consumable together with all information required for ordering them from manufacturers. Sub-Suppliers of individual components shall be clearly Communication address shall be indicated for each reference.
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identified.
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ELECTRICAL LOAD DATA
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Datasheet for Medium voltage Squirrel Cage induction motor ELECTRICAL DESIGN DATA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
Motor tag no. Voltage (V) 415V ± 10% Phase 3 Frequency(Hz.) 50Hz ± 3% System Fault level (KA) 50kA for 1 sec. Method of starting DOL Phase Three Connection Delta No. of terminals 6 Design Ambient temp© 50 º C Temp. rise 70 º C Cable size (mm ²) As per data sheet Type As per data sheet Enclosure type IP55 Cooling TEFC Insulation class F Hazardous Area classification/Gas Group: Not applicable (Safe area) Type of explosion protection (Ex(n)/Ex(e)/Ex(d): Not applicable Suggested Motor Rating in KW/Manufacturer Applicable Standards: Nalco’s Stand. Specs. for MV Motor Shaft kw/ kw at end of curve Speed/Rotation of equipment from Coupling End Starting/max. Torque required (mkg) WK² of equipment Including/excluding flywheel (kgm ²) Thrust up/down (kg) Equipment/ coupling type Starting Condition- On no load/Under loaded Condition Technical particulars from motor manufacturer Manufacturer KW Rating No .of poles Frame designation Mounting Full load speed (rpm) Full load Torque (mkg) Starting torque as % of full load torque Full load current (A) Starting current at 100% Voltage (A) Break down or pull out torque % Rotation viewed from coupling end Starting time at 80 % V (sec.) Starting time at 100 % V (sec.) Time (Te) for increased safety motors at 100 % Voltage (sec.) Locked rotor withstand time cold/hot at 80% V (sec.) At 100 % V (sec.) WK ² of motor (kg m ²) Power factor at 100 % load Power Factor at 75% load Efficiency at 100 % load Efficiency AT 75% load Space heater watts/ volts Bearing type/ no. DE Bearing type/ no. NDE Type of Lubrication Weight of motor (kg) Canopy Required/ Not required
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13
14
15
16
1 18 7 Motor Rated KW
12
Speed rpm
11
Mot. Dir. Of Rot. (From
10
Driver inl. Yes/No
Type of equip.: pump/Cent. Comp./Recip. Comp./Blower
9
End of Curve/max. KW Min. Rec. KW of Mot.
Normal /stand .by
8
Desgn. Abs. shaft KW
Service
7
GD² of Rot. Part kg-m²
Tag no.
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6
Rated Speed RPM
5
Drive arrgmt.
4
Mount.
3
Equipt. Status
2
Manuf. Of equip.
1
Sl.no
Starting Time calculations shall be based on Operating conditions specified in bid package i.e. open valve/ closed valve conditions, at No Load/ Under Load etc. as applicable.
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ACCEPTABLE VENDORS: ELECTRICAL WQUIPMENT VENDORS FOR ELECTRICAL EQUIPMENT USED IN ELECTRICAL SYSTEM SHALL BE SELECTED OUT OF FOLLOWING LIST ONLY: 1.
M.V. SWITCH BOARDS DRAWOUT (MCC)
S.NO. 1. 2. 3. 4. 2.
VENDORS L&T LTD. ALSTOM BHARTIYA INDUSTRIES LTD SCHNEIDER M.V. POWER & CONTROL CABLES
S.NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 3.
VENDORS LAPP KABLE FINOLEX CABLE LIMITED GLOSTER INDUSTRIES LIMITED INDUSTRIAL CABLE INDIA LIMITED NICCO CORPORATION LIMITED DELTON CABL UNIVERSAL CABLE INDCAB TORRENT CABLE LIMITED CCI CONTROL STATIONS- WEATHER PROOF
S.NO. 1. 2. 4.
VENDORS RITTAL SCHNEIDER MOTORS- INDUCTION M.V.
S.NO. VENDORS 1. KIRLOSKAR ELECTRIC CO LTD., NEW DELHI 2. NGEF LTD., NEW DELHI 3. SIEMENS LTD., MUMBI 4. ALSTOM LTD., NEW DELHI 5. ASEA BROWN BOVERI, NEW DELHI 6. SEW EURODRIVE* 7. DEMAG CRANES AND COMPONENTS* *These motors shall be considered for motor with integral brake and geared motor only.
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LOCAL POWER ISOLATION CABINETS FOR 415V MOTORS
S.NO. 1. 2.
6.
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ADDITIONAL LIQUID PITCH HANDLING SYSTEM
VENDORS SOCOMEC FERRAZ
VARIABLE FREQUENCY DRIVE AND ITS ENCLOSURE
S.NO. 1. 2.
SMELTER DIVISION
VENDORS DANFOSS WITH RITTAL ENCLOSURE ROCKWELL WITH RITTAL ENCLOSURE
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APPROVED MAKES: COMPONENTS/ DEVICES/INSTALLATION MATERIAL A. Make of Electrical Components/ Devices used in Switchboard/ Control Panels and miscellaneous installation material shall be selected out of following approved makes only. S.No. ITEM/EQUIPMENTS VENDORS 1. HV Outdoor Isolator ( upto Alliance /Kiran Textile/ Hivelm/ Driescher & Panicker/ Swgr. Manufacturing co./ 33 KV class) GECA/S&S Swgr./ABB 2. 3. 4. 5. 6.
H.V. Indoor isolators /Load Break Switches Heavy Duty Switches for MCC Incoming Circuits Air Circuit Breakers Switch-Fuses-Unit
Driescher & Panicker/NGEF/ Siemens/ ABB SCHNEIDER/ /L&T L&T/GECA/Siemens( 3WN type only) L&T/GE/ SCHNEIDER
7.
Heavy Duty Switches/ Fuse Switches H.V.CTs/PTs
8. 9.
M.V.CTs / PTs Breaker Control Switches
AEP/Jyoti /L&T/Siemens/ Precise/Gilbert GE/ RECOM/ EASUN/ Jyoti/ SCHNEIDER
10. 11. 12. 13. 14. 15. 16.
GE/Siemens/Kaycee/Jyoti/L&T/SCHNEIDER L&T / SCHNEIDER L&T / SCHNEIDER / LEGRAND/ INDOASIAN L&T / SCHNEIDER/ INDOASIAN Siemens/L&T/GE/Ferraz L&T/ SCHNEIDER L&T/ SCHNEIDER
23.
Other Control Switches MCCBs MCBs ELCBs Fuses Power Contactors Bi-Metallic Over Load Relays Timers Protection Relays Auxiliary Relays Timers (Static) for Lighting Control Meters Push Button / Indicating Lamps H.V.Busduct
24.
M.V.Busduct
Siemens/ L&T / GE / NGEF/ VOLTAS
17. 18. 19. 20. 21 22.
SMELTER DIVISION
Siemens/ L&T/GE/SCHNEIDER AEP/ Jyoti/ Voltas/ABB/ Elect.trafo.Co. Bhopal/ ECS, Vadodara
L&T/ SCHNEIDER ALSTOM/ SCHNEIDER L&T / SCHNEIDER L&T / SCHNEIDER / AEP/ IMP/ RISHAB/ L&T / SCHNEIDER BHEL/ Jyoti/ Voltas /United Electric
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S.No. 25.
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27.
ITEM/EQUIPMENTS VENDORS Philips/Crompton/Bajaj/ GE/ GEWISS Lighting Fixtures for NonHazardous Area and Hazardous Area Cable Glands for Hazardous LAPP / WAGO Area H.V. Cable termination and Jointing Kits up to 11(KV)(E) GRADE • Heat Shrinking • Denson/ Raychem/ Xicon • Taperx • M-Seal • Push-On • M-Seal/ CCI • Cold Shrinking • 3-M
28. 29.
Buchholz Relay Magnetic Oil Level Gauge
30.
Oil Temperature Indicator
26.
31.
B. C. S.No. 1. 2.
3. 4.
EE/ Prayog/ Instrument and control/ Sukrut Udhyog
M.Guru/ Scientific Control/ Perfect control/ Precise measurement/ PRAYOG Winding Temperature Indicator Accurate Control (UK)/ Perfect
Vendor list for switchyard equipment: ITEM/EQUIPMENTS EHV Outdoor Circuit Breakers EHV Outdoor Isolator and Earthing Switch EHV Outdoor CTs/PTs Lightning Arrestors
VENDORS BHEL/CGL/TELK/ABB EHV outdoor isolator and earthing switch/ Drielscher and Panicker/ GECA/ Hivelm / Oblum Electrical Ind./Switchgear AEP/ ABB /BHEL /CGL /TELK W.S Insulator/ Elpro(IGE)/ Oblum/ CGL
Note: For make of items not covered herein, prior approval of Nalco is mandatory.
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Vendor Data Requirement (Electrical) for Off-Sites Package Units Document
With bid
List of deviations to specifications & Data Sheets (for data specified by purchaser) Electrical Load Data Guaranteed Power consumption and preliminary Single Line Diagram Single Line Diagram Emergency power requirement Control supply requirement Motor Data Sheets & other Data Sheets Operation/ Maintenance Manual Technical details for major equipments Purchase requirements for major equipments List of recommended spares Type Test Certificates Catalogues and Brochures Bill of Material Equipment Layout GA Drawings of Switchgear Interconnection/ Wiring Diagrams Area classification drawings Lighting design calculations Interface with main plant Test Certificates Cable Layout Earthing Layout Lighting Layout List of Drawings/ Documents along schedule of submission Number and Rating of 415 V Feeders required from Nalco’s Switchboard
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For review
Reference and records
*
*
* *
*
* * * * * *
* * * * *
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Notes:-
1.
Unless otherwise agreed, the number of copies of various drawings and documents shall be as below: a) With bids-Same as the number of copies of bids b) Post order submission- For Review/Records- Four copies c) Final documents- Six prints, One Reproducible, One Electronic File in CAD. For further details, vendor shall discuss and take approval for quality data requirements.
2.
18
17
16
Speed RPM
MOTOR Rated
Mot. dir. of
15 Driver incl Yes
14
13
End of curve/ max kw Min Rec. KW of
12 Design abs shift
11 GD²of Rot part
10 Rated Speed
9 Drive Arrgmt
8 Mounting
7 Eqpt. status
6 Manufact ure of
5 Type of eqpt.:
Normal /Std.by
Service
Tag.No
S.no
SMELTER DIVISION
4
Vendor shall furnish electrical drawings prepared by them in AUTOCAD and on DXF format which can be read/ modified on AUTOCAD. Sub- vendor drawings may be as per their standards.
3
4.
2
Vendor shall submit schedule of drawings and documents within 15 days after placement of FOI/LOI.
1
3.
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SCOPE OF WORK AND STANDARD SPECIFICATION OF INSTRUMENTATION AND CONTROL SYSTEMS
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SCOPE OF WORK: The scope of work shall consist of design, engineering, supply, installation, field calibration, testing, commissioning of complete instrumentation and control system with all accessories and material for additional liquid coal tar pitch storage tank with transfer facilities for Green Anode Plant, in accordance with the specification and drawings enclosed with this requisition on turnkey basis. The equipments and services to be provided shall include but not limited to the following:
1.1
Vendor will have to submit detailed design of Control system, material selection, sizing and selection of the proper instruments for the proposed system.
1.2
Vendor shall clearly define the operational philosophy suggested by them, which shall be in line with requirements specified in the job specifications. Vendor shall also clearly indicate the provision of control panels, and control systems required for their package along with their offer.
2.0
Design Philosophy
2.1
The control philosophy for Instrumentation shall be complete in every respect and liberal to the extent of providing data on all operations end variables sufficient for the safe, efficient and easy operation, start up and shut down of t h e s ys t e m.
2.2
The CS is to be designed to control the important parameters like flow, temperature, pressure and switch-over to standby equipments in case of fault.
2.3
For the operation and control of the heating system with related auxiliary equipment, all requisite Instruments to be supplied by vendor. These will cover ( but not be restricted to ) i)
Pressure measurement
ii)
Flow measurement
iii)
Temperature measurement
iv)
Level measurement The quantities, ratings and range are to be assessed by the vendor based on
control philosophy and the general specification of instruments enclosed herewith. 2.4
The design, engineering, installation and testing shall be in generally in accordance with ISA, API specifications and practices and other applicable standards like BIS, IBR etc. shall in general, conform to appropriate ASTM or e qu ival en t standards.
2.5
All instruments and equipments shall be suitable for use in a hot, humid and tropical industrial climate in which corrosive gases and/or chemicals may be present. As a minimum, all instruments and enclosures in field shall be dust proof and weatherproof to IP-55 as per IEC-529/IS-2147 and secure against the ingress of DOCUMENT TITLE
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fames, dampness, insects and vermin. All external surfaces shall be suitably treated to provide p ro t e c ti on against corrosive plant atmosphere. 2.6
Instrument Requirements for classified area: a)
All electronic/electrical instruments and equipments shall be su ita ble for area classification as per IEC codes and shall be certified by any recognised authority like BASEEFA. CENELEC.FM, PTB, CMRI etc.
b)
Certified in trin sically safe equipment as per IEC-79-11 shall be used, in general, in hazardous area. In case intrinsically safe equipment is not available, flame proof enclosures as per IEC-79.01 may be considered.
c)
Junction boxes and accessories required for flameproof instruments shall also be certified flameproof.
d)
All non flame proof panels and cabinets installed in classified area shall be purged as per requirements specified in NFPA-496, as a minimum.
e)
2.7
Other type of protection as specified in IEC-79 shall not be used.
Following units of measurement shall be applicable, unless indicated specifically otherwise: Flow
Pressure/Vacuum
2.9
Liquid
m3/h
Steam
kg/h
Gas & Vapour
Nm3/h
Gauge/vacuum
kg/cm2, mmWC
Temperature
0
Level
%
Viscosity
mPa.s
C ( cP )
Ranges for instruments shall be selected in general, such that in normal process operation the indication is between 40% to 60% of span for linear and 60% to 80% of span for square root inputs.
2.10
Ranges for process switches shall be selected, in general, such that the set point falls preferably in the middle 30% of full adjustable range i.e. the set point snail fall between 35% and 65% of adjustable range.
2.11
All controllers shall have facility for bumpless auto-manual and manual-auto transfer and set point adjustment. Flow, pressure and level controller shall be provided with proportional plus integral action, while temperature controller with proportional plus integral plus derivative action.
2.12
Field mounted direct actuated Flow and Temperature switches shall not be used Instead receiver switch/trip amplifier shall be used along with flow element/ temperature element.
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2.13
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Intrinsically Safe System Requirements Following points must be considered while designing an in trin sically safe system. a)
All intrinsic safety barriers shall be active type isolating barriers only Zener barriers shall only be used if unavoidable.
b)
Barriers must be selected based on entity concept.
Cable parameters shall
also be considered while matching entity parameters. c)
Each instrument in the hazardous area and the intrinsic barrier shall be certified for intrinsic safety by any statutory authority.
d)
Each input and output in a loop shall have separate barrier.
No barrier snail
be shared between two loops or input/outputs. e)
Any intrinsically safe loop requiring any device to be connected in the hazardous side permanently or temporarily, shall also be intrinsically safe.
f)
Configuration tools whenever required for any intrin sically safe item which forms part of the intrinsically safe item shall also be certified in t rin si cal ly safe.
f) 2.14
All barriers shall be of MTL make or equivalent.
Power supply and their distribution: a)
Power supply shall be made available at the following voltage levels, unless otherwise specified; For Instruments, Control Systems
1 10V ac ± 10%
Analyzers
50Hz ±3Hz
Solenoid Valves, Relays, lamps
110V dc ± 10%
Input interrogation voltage
110Vdc±10%
Panel/cabinets lighting
240V ac - 10%
In case 24 V dc is required for Input interrogation, relays and lamps etc same shall be generally by the bidder using dual Redundant power packs (110 V dc to 24 V dc converter). No 24 V dc feeder shall be supplied unless indicated specifically in the job specifications. b)
All instruments, PLC system shall be able to operate at the following UPS specification ; Voltage level
: 110V ac ± 10%
Frequency
: 50 Hz +3 Hz
Switch over time : 5 milli seconds. c)
Power feeders shall be supplied to the bidder at only one location. All further distribution within the package shall be taken care of by the bidder.
d)
Instrument power circuits shall be individually protected from fault with the
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help of fuses. Power supply to the individual instrument shall be disconnected with the help of DPST switch and protected with the help of fuses. Miniature circuit breakers (MCB's) may be selected in place of switch fuse unit in case protection is provided for overload protection.
3.0
Automation Philosophy: The control system shall be in line with the existing plant system. However, there will be two modes of control system from a selector switch as per following: a) Local Mode This mode is mainly used during maintenance operations: Each drive can only be operated locally, using the local push buttons. Interlocks through the PLC (Programmable Logic Controller) are no more operating. Only the electrically wired interlocks will remain effective. The local stop push button and the emergency switch are the minimal securities for each motor. b) Remote Mode The control of equipments will be through PLC SCADA screen. In this mode two levels of control will be provided. Level 1(Manual):- Each equipment will start and stop individually from supervisory system without any interlocks. Level 2 (Auto):- Equipments shall start and stop from supervisory system with interlocks as per control Logic.
4.0
Control system:
4.1
The control system will be configured in the PLC/SLC with their interlocks/ operations/ alarms/ trips/functions on the basis of control philosophy of the system. The supply, installation and commissioning of PC-PLC system will be in the scope of the vendor.
4.2
4.3
The following parameters are to be measured and indicated in the PC-PLC system: i)
Pressure in main pipe line ( after pump)
ii)
Pressure in main line ( before pump) .
iii)
Flow totaliser ( in outlet line) .
iv)
Level of Pitch in tank .
v)
Differential pressure across the filter in both inlet and outlet line
vi)
Temperature of HTF in both inlet & outlet line
vii)
Temperature of Liquid pitch at outlet
In addition to above indications, following indications, annunciations, alarms DOCUMENT TITLE
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and control to be provided in GAP Control room. Alarm annunciation system to be as output from PLC based Control System. Audio alarm and one emergency STOP button is to be provided at the PLC console panel. i) Indication: •
Indication of inlet and outlet pump running
•
Indication of Circulating Pump running
•
Indication of HTM Pump running
•
Valves position ON/OFF
ii) Fault Annunciations : Pump/Motor fault
•
iii) Alarms • 4.4
HTF high temperature, Alarm & Trip
The system shall be designed fail safe and shall meet the following requirements, as a minimum :a)
All initiating contacts shall be close under normal conditions and shall open under abnormal conditions.
b)
All relays and solenoid valves shall be energised under normal conditions and shall de-energise under abnormal conditions.
c)
Emergency shut down switch contacts shall be wired in series with the final actuating device to ensure positive shutdown.
5.0
Alarm Philosophy a)
Adequate alarms shall be provided to give audible and visual warning of anyprocess and machine malfunction in the package.
b)
All trips shall have a pre-trip warning alarm in addition to alarm at the trip condition.
c)
AH package alarms including pre-trip warning alarms and trip alarms (shutdown alarms) shall be annunciated on the local panel.
d)
Printers are to be provided, all alarms shall be printed as and when they appear, in the sequence of their occurrence.
e)
Common pre-warning and common trip Alarm contact for the package shall be provided for remote annunciation.
Additional al a r m contacts shall be
provided when specified. f)
‘Fail-safe' type with normally closed alarm contacts shall be used.
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GENERAL SPECIFICATION OF INSTRUMENTS AND CONTROL SYSTEM
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1.0
PC-PLC System:
1.1
The PC-PLC system shall consist of : •
PLC/SLC
•
Power supply
•
Analog and digital flex I/Os
•
Networking to the existing PLC
•
PC based MMI station (Latest Desktop PC with 19” colour LCD monitor)
•
Inkjet colour printer
The required quantity and type of CPU, O/Is, networking cards, panels etc are to be assessed by the vendor. The PLC/SLC is also to be hooked up with the existing A-B PLC 5/40 through the Ethernet Hub (HP Procurve switch 2124). The software shall include the operating system (Windows XP or latest windows version) and application program. The application program shall include software for performing functions like interlock and shutdown logic, programming/program modification, documentation etc. Two copies
of
application program and two set of licensed system software shall be supplied. 1.2
The PC-PLC system shall be housed in suitable Rittal make panel. The PC-PLC system shall be installed in the existing GAP Control room located at +9 M level. Signals from field instruments shall be interfaced to the PC-PLC system through suitable control cables. Brand preference: Rockwell/ Siemens
2.0
Electronic Instruments
2.1
All electronic instruments requiring separate power supply, shall generally operate on 220 V 50 Hz. Instruments operating at 24 V dc shall also be acceptable.
2.2
Electronic transmitters shall generally be two wire type. These shall have transmission/output signal of 4-20 mA dc and shall be capable of delivering rated current into external load of at least 600 ohms when powered with 24 V dc nominal voltage.
2.3
Smart transmitter when selected, shall be used in analog output mode. Digital integration shall be avoided unless specified otherwise.
2.4
All receiver instruments shall be microprocessor based and shall operate on voltage input of 0.25 to 1.25 V, 1 to 5 V, or 0 to 10 V dc, in general.
2.5
The design of electronic instruments shall be in compliance with the electromagnetic compatibility requirements as per IEC - 801.
2.6
Pneumatic Instruments shall operate on air supply of 1.4 kg/cm2g and shall have transmission and output signal of 0.2 to 1.0 kg/cm2g.
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Instrument air quality shall be as per ISA-S7.3 and free from corrosive, hazardous and toxic contaminants.
2.8
Make of Instruments/ transmitter/ indicators/ gauges: TATA Honeywell/ VEGA/ Fisher Rouse-mount/ Waaree.
2.9
Make of temperature sensors: Nagman/ Tempcon/ Toshniwal/ Waaree
3.0
Panel Board Instruments:
3.1
Panel board instruments shall generally be multibin subminiature 6" x 3", except recorders, which shall preferably be 6" x 6". Instruments like microprocessor based recorders, temperature scanners etc. shall be as per manufacturer standards.
3.2
Panel board instruments shall have the following graduations, in general; Flow with DP cells Rotameters Pressure Level Temperature
,
: :
0 to 10 square root 1 to 10 linear
:
Direct Reading :
:
0 to 100 Linear Direct Reading.
Multiplying factors for flow scales shall be specified on manufacturer's name plate. Recorder charts shall be dual graduated, in general, in 0 to 10 square root and in 0 to 100 linear. 3.3
Subminiature recorders shall have 100 mm strip chart with chart speed of 25 mm/h. Microprocessor based recorders shall have strip chart of 250 mm approx. and chart speed of 50 mm/h with a provision to change speed at site.
3.4
Annunciators, in general, shall be solid state type with plug in modules, in a cabinet with back lighted engraved windows and integral power supply. Alarm logic module shall be single channel type. In case multi-input alarm module are selected, only one channel shall be used. Intrinsically safe annunciator circuit, when used, shall have power supply unit in a safe area. The design of the alarm annunciator system shall be such that transient alarms of less than 330 milliseconds duration shall be automatically rejected.
4.0
Field transmitters
4.1
All field transmitters shall have an accuracy of 0.25 7c of span and shall be provided with output meter/output gauge at the signal output.
4.2
Smart transmitters when used shall be used in analog mode only unless specified otherwise. At least one number of hand held configurator shall be supplied as a minimum.
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Smart transmitters when specified shall have an accuracy ±0.1% of span, as a minimum.
5.0 5.1
Temperature Instruments Thermo wells a)
All temperature elements shall be provided with thermowells fabricated out of bar stock of minimum SS 304 material. The base of the thermowells shall be chosen to fit the instrument without air gap for minimising measuring lag.
b)
Built-up thermowells shall be used in low pressure and low velocity services like in fired heaters and also where thermowell immersion lengths greater than 500 mm are required.
c)
Immersion length of thermowells shall be as follows; Line Size
Immersion length
From 4" to 6'
280 mm
From 8" onwards
320 mm
Vessels / columns
400 mm
In special applications, not covered above, vendor shall decide the immersion length based on actual requirements. Immersion length is based on 200 mm length between flange face and inner wall of pipe. d)
Any pipe line less than 4" nominal bore shall be blown to 4" size to install thermowell.
5.2
Temperature Gauges a)
Local temperature gauges shall be liquid/ vapour gas filled type in general and shall be manufactured as per relevant SAMA Class. Bimetallic gauges can also be considered if approved by purchaser. The temperature bulb shall be of stainless steel construction in any case.
b)
All local temperature gauges shall have 150 mm dial size. The bulb size shall be selected to suit the thermowell.
c)
All gauges shall be of weatherproof construction.
d)
In vibrating service filled type temperature gauges with capillary extension shall only be used. Capillary tubing shall be of SS304 as a minimum with stainless steel flexible armouring.
e)
f)
Temperature gauges shall have accuracy of ± 1 % URV
Bimetallic type dial thermometers shall be avoided where excessive
vibrations are encountered, such as compressors. Only filled type with capillary extension shall be used in such cases. Capillary tubing shall be
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minimum of 304SS with stainless steel flexible armouring, and PVC covering over armour. g)
Thermometer stem adjustable gland with union connection and bushing shall be suitable for 1/2" NPTF connection.
5.3
Temperature Elements a)
For
remote
temperature
indication/recording/control/switch
etc.,
thermocouples or resistance temperature detector (RTD) shall be used depending on the process requirements. Elements shall be spring loaded, mineral insulated and shall have stainless steel sheath. b)
Thermocouple assemblies shall be furnished with weatherproof screw type heads.
c)
Thermocouples shall be as per IEC-584-2/IS-7358 and shall have a wire size of 18 AWG for single and 20 AWG for duplex thermocouples. These shall be magnesium oxide (MgO) filled ungrounded type, unless necessary otherwise. The type of thermocouple shall be selected based on temperature. Following guidelines shall be followed :Copper-Constantan (ISA-Type-T)
:
(-) 200 to 2O0°C
Chromel-Constantan (ISA-Type-E)
:
(-) 200 to 6O0cC
Iron- Constantan (ISA-Type-J)
:
0 to 600°C
Chrome!-Alumel (ISA-Type-K)
:
600 to 1200X
PiaunumRhodium-Platinum (ISA Type-S) : 600 to 1600°C The design of thermocouple assembles sh all be such that replacement on line is possible. d)
RTD (Resistance Temperature Detecter) shall be platinum element 3 wire type with 100 ohms resistance at 0°C calibrated as per IEC 751/DIN 43760. RTD shall be used within a temperature range of -200 to 650°C. Three wire system shall be adopted in connecting the element.
e)
RTD shall be used where accuracies of the order of 0.25% or better and smaller measuring spans are required.
f) 5.4
Twin element sensors, if used, shall have two separate cable entries.
Temperature Transmitter a)
Unless specified otherwise, temperature transmitters, shall be panel/rack mounted type only. In case, field mounted transmitters are specified, head mounted transmitters shall be avoided.
b)
Temperature transmitters shall have a built-in linearising function to produce
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an output linear to temperature range. c)
Temperature transmitters shall have an accuracy of ±0.25% of URV as a minimum.
6.0
Pressure Instruments
6.1
Pressure Gauges a)
Pressure gauge dial shall be white, non rusting plastic with black figures. The dial face shall be marked with pressure element material. Pointers shall have micrometer adjustment.
b)
Pressure gauges shall be weatherproof with dial size of 150 mm and shall have features like screwed bezels, externally adjustable zero, over range protection and blowout discs. Pressure gauge sensing element shall be of SS 316 and movement of SS 304, as a minimum.
c)
Pressure gauges shall have an accuracy of ± 1 % of URV as a minimum. Differential pressures gauges may have an accuracy of ±2% of URV.
d)
Over range protector and pulsation dampner, whenever used, shall be of SS 304. as a minimum. Pulsation dampner shall be used for all pulsating services. It shall be floating pin type, externally mounted and externally adjustable.
e)
All pressure gauges with max. operating pressure exceeding 60 kg/cm2 shall be solid front type.
f)
Connection snail normally be 1/ 2" NPTM bottom.
g)
Cases shall normally be cast aluminium alloy or black phenol and weatherproof to IP-55 as per IEC-529/1S-2147. Blow-out discs shall be provided.
h)
Ranges shall be so specified that the gauge normally operates in the middle third of the scale and shall conform to IS-3624 standard dials, wherever possible.
i)
Diaphragm seals, filled type or mechanical type shall be furnished where plugging of the element may occur or where suitable material is not available in highly corrosive services. When chemical seals are required, they shall be of the clean out type with flushing connection.
j)
Receiver pressure gauges for local transmitter output indication shall have 100 mm dial with stainless steel element and 1/4" NPTM connection.
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Pressure/Differential Pressure Transmitters a)
Pressure/differential pressure transmitter shall have electronic state-of-art capacitance or any other type of sensor meeting all functional specifications. Element material for transmitters shall be SS316, as a minimum, and shall be able to withstand over pressure of at least 30% of range or maximum working pressure which ever is higher.
b)
All transmitters shall have an integral output meter. Remote mounted meters may be provided if required in addition.
c)
All transmitters shall have an accuracy of ±0.25% of URV, as a minimum. Whenever smart transmitters are specified/supplied, accuracy shall be governed by clause 2.19 (c).
d)
Diaphragm sell element with capillary shall be used for congealing, corrosive and highly viscous services.
6.3
Pressure Switches a)
Pressure switches shall have either diaphragm or bellow type of process element with SS 316 material of construction as a minimum. Switch type shall be sealed micro type with contact rating suitable for specific application.
b)
Pressure switches shall be blind type with 1/2 NPTF process connection and shall be operative in full specified range. The switch differential shall be selected as per operating conditions.
c)
Pressure switches shall have repeatability of +0.5% of URV, as a minimum.
d)
Receiver pressure shall have SS316 bellows as measuring element with 1/4" NPTF connection.
7.0
Level Instruments
7.1
Level gauges a)
All gauge glasses shall be steel armoured reflex or transparent type with body and cover material of forged carbon steel as a minimum and shall have tempered borosilicate glass with asbestos or other suitable gasket. Transparent type of gauges shall be provided with integral illuminators operating at 230V, 50Hz supply and suitable for electrical area classification specified. All gauge glasses must have a rating equal to or more than the vessel design pressure and temperature.
b)
Reflex type will be used for clean and colourless liquids, except liquids level interface. For low temperature, low boiling point service, large chamber type will be used. Transparent type w ill be used on acid, caustic, dirty or
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viscous, coloured liquids and liquid interface. Transparent type with Mica or Kel-F shields shall be used for treated water, boiler and condensate services, and for corrosive liquids which will attack glass. Tubular gauge glasses shall, in general, not be used. They may be used for non-hazardous services at ambient temperature and low pressures. c)
Large chamber gauges with frost shields shall be provided for cold services below 0°C. Heating jacket shall be provided for viscous liquids.
d)
All gauges shall have top and bottom chamber connections, unless otherwise specified. In addition each gauge shall be provided with ball check valves and pipe union. The visible range of level gauge shall be selected to cover the complete operating level as well as measuring range of the other level instruments provided for the same purpose.
e)
Gauge glass cocks shall be forged off-set type with an integral ball check and back seating stem. Primary isolation valves are normally required in addition to the gauge glass cocks, except on vented tanks containing harmless liquids. Where the process fluid tends to foul the cocks internals and create plugging or where leakage is a problem, gauge valve may be eliminated. On low temperature service with liquids having very high vapour pressure at ambient temperature safety valve shall be provided at the vent connection of the gauge glass. Gauge cocks may be deleted or ball checks omitted when the fluid is not toxic, corrosive, inflammable or at high pressure and when there is a possibility of sluggish action.
f)
For level gauging in very viscous liquids and liquids with crystals, float operated magnetic gauges with 2" (50 mm) flanged end connections, shall be used.
7.2
Level Transmitter a)
External displacer type instruments with side-side connections and rotatable head, shall normally be used for level measurement up to 1219 mm. Sidebottom connections are preferred where RTJ flanges are required. Internal displacer type of level transmitters shall be avoided unless application necessitates its use.
b)
All displacer type of level transmitters shall be of torque tube type with torque tube material of inconel, as a minimum.
c)
In general, displacer type instruments shall be used with displacer lengths of
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356 mm, 813 mm and 1219 mm. For interface level measurement, displacer type instruments shall only be used. d)
Differential pressure transmitter shall be used for level measurement above 1219 mm, for services requiring purge or where liquid might boil in external portion.
e)
Differential Pressure transmitters for use on corrosive or fouling service shall generally be diaphragm wafer with extended filled capillary type. Rush or extended diaphragm type differential pressure transmitter shall be considered for special applications only. Diaphragm material shall normally be stainless steel or any other special alloy.
f)
Dip Tube type level transmitters may be used on corrosive, congealing, slurry services where suitable diaphragm transmitter is difficult to obtain.
7.3
Level Switch a)
Level switches shall generally be external ball float type with flanged head. Internal float/displacer type level switches shall only be used if ball float type is not possible, like in viscous services and in underground tanks.
b)
Switch shall be sealed micro type with contact rating suitable for the specific application.
c)
Level switch shall be furnished with SPDT contacts with adjustable differential, unless otherwise specified.
7.4
Tank Level Instruments a)
Mechanical float type gauge shall be used for atmosphere tanks and vessels where level measurement accuracy requirement is of the order of ±2 mm. Seal chamber shall be used where tank contents are toxic or tank is blanketed.
b)
Servo controlled gauges shall be used for level measurement of pressurised tanks/vessels/spheres requiring remote signal transmission and better level measurement accuracies. Level data transmission signal shall be digital only. Servo type instruments shall have 6" process connection with 12" dia still wall.
c)
The tank side indicator for both types of gauges shall have hoisting facility. All tank level gauges shall have side mounted indicator-counter type for mechanical float type and solid state digital for servo controlled level gauge.
d)
The wetted material like float, displacer, tape, wire etc. shall generally be 316 SS.
e)
The accessories for servo-controlled level gauge shall include calibration
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chamber and isolation ball valves for pressurised tanks. f)
Other Special type of level instruments like Radar, ultrasonic, hydrostatic, nucleonic. capacitance, conductivity type shall be used as necessitated by application requirements.
8.0
Flow Instruments
8.1
Orifice Plates a)
Flow measurement shall normally be carried out using thin
square
edged concentric orifice plate mounted between a pair of weld neck flanges of minimum 300 pounds ANSI rating for line size 2" and above. Flange taps shall be used for line sizes up to 12" while D-D/2 taps shall be used for line sizes 14" and above. The material of the orifice plates shall be normally SS 316, as a minimum. Quadrant edge or quarter circle orifice plates shall be used for highly viscous liquids and for pipe Reynold number below 10.000. Conical entrance type or" orifice plates shall preferably be used for very high viscous l i qu i d s unto throat Reynolds number of 250. These shall be fabricated as per BS 1042 Part 1 Vent and Drain holes shall be provided wherever necessary. b)
Sizing of orifice plate shall be carried out in accordance with ISO-5167. Other sizing methods like AGA Repel No.3, BS-1042, 'Flow measurement-Engineering Handbook' by R.W. Miller shall be used when specified.
c)
Honed metering runs or integral office type transmitter shall be used in lines with Vh" (40 mm) nominal diameter or below.
d)
Upstream and downstream straight length shall be provided based on maximum d/D ratio of 0.75. in general. Where it is difficult to meet this requirement, the actual d/D ratio can be considered for reducing the straight length as permitted by the codes.
e)
Meter taps shall be horizontal for liquids, condensible vapours and steam.The taps shall be on top for gas, non-condensible vapour, or liquids which boil at or below the maximum design ambient temperature at operating pressure. Where piping clearances are a factor, taps may be located upto 45° below the horizontal centre line for condensible vapour, liquid and steam. The taps may be located upto 60° from vertical for gas and non condensible vapour.
8.2
Variable
area
flow
meters
or
rotameters
shall
be
as
per
ISA-RP
16.1,
16.2,16.3.16.4,16.5 and 16.6 and shall be used for viscous or corrosive services or
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where rangeability in flow precludes the use of an orifice. Metal tube rotameters shall be used for all process fluids. External devices for indicating or transmitting shall be magnetically coupled to the float or extension. Glass tube rotameters shall be used for low pressure utility services for local indication and where line size is 11/2" (40 mm) or less. Glass tube rotameters shall not be used if outlet line is connected to a line or vessel containing hazardous or toxic fluid unless a check valve is installed at the downstream side of rotameter. 8.3
Turbine and positive displacement meters shall be used for accurate flow integration for blending application, custody transfer etc.
8.4
Integral orifice meters, when used, shall be installed with block and bypass valves.
8.5
Magnetic tvpe flow meters shall be used for electrically conducive slurry corrosive services and shall be installed with line size bypass, wi t h block and clean out valves, at the lowest point in piping to ensure that meter run is always l i qu i d filled.
8.5
Target meters shall be considered for highly viscous hydrocarbon streams such as asphalt, tar, polymers etc.
8.6
Vortex meter shall be considered where high rangeability is the prime requirement.
8.7
Ultrasonic flow measurement shall be considered where non-intrusive flow measuring is required.
8.8
Averaging pitot tube shall be considered for low pressure loss, high velocity steam, large diameter lines and air ducts.
9.0
Control Valves
9.1
Control valves shall normally be globe type, single seated or double seated. Other valve types like butterfly ball, rotary plug, angle or 3 way etc., shall be selected as per service requirements.
9.2
Control valve sizing shall be carried out as per ISA S75-01. The valve shall permit up to 150% of normal flow or 110% of maximum flow, whichever is higher. In general, control valves shall be sized so that the valve opening is as noted below ; At max. flow
9.3
:
about 90% open
At normal flow :
about 75% open
At minimum flow
:
about 20% open.
Flanged control valves shall be used. Body material, body rating and flange rating, shall be as per piping specifications as a minimum.
9.4
Minimum control valve body size shall be 1" in general. Reduced trims can also be considered. Body size shall be limited to 1",1-1/2", 2", 3",4",6",8",10", and 12". Higher sizes may be used where ever necessary.
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Material used for trim shall be SS 316, as a minimum. For higher pressure drops (greater than 10kg/cm2g), flashing, cavitating, erosive and slurry services and, in general, all steam services, trim shall be stellited. (wetted parts like seat ring,valve plug, plug guide, plug stem, guide busing and cage are being termed as trim).
9.6
Trim characteristics shall be equal percentage type unless required otherwise. Control valve plugs shall be top and bottom guided for double seated valves and heavy top guided for single seated valves.
9.7
Anti-cavitation trim shall be selected wherever cavitation is expected in the valve.
9.8
Noise from control valve during operation shall be l i m i t e d to OSHA specified level or better. The maximum allowable noise is 90 dBA SPL (Sound Pressure Level). Source treatment for noise shall be preferred by using special trims like anti-noise trims, in case noise exceeds the specified level. Other methods based on merit is permissible.
9.9
Valve seat leakage shall be as per ANSI/FCI 70.2 and shall be selected with due consideration to meet the requirement.
9.10
Flanged bolted type gland packing boxes shall be used. Packing shall normally be PTFE on liquid and gas service up to 200°C. PTFE impregnated asbestos shall be used above 200°C and up to 260°C with lubricator preferably. Graphite impregnated asbestos or equal with lubricator, shall be used on steam service and temperature above 260°C.
9.11
Elbows seal shall be used where it is required to isolate the packing from the process fluid or where no leakage to atmosphere can be tolerated like toxic, explosive and precious fluids.
9.12
Block and bypass valves shall be installed with all control valves up to and including 2" size except for butterfly valves, 3 way valves and slurry and freezing service. Hand wheel shall be provided for all other sizes and services. No by-pass valve or hand wheel shall be used for shutdown valves.
9.13
Valve actuator shall be pneumatic spring opposed diaphragm type, in general. Piston type actuators may be used for very high shut off pressure requirements. Additional equipment necessary to meet fail safe condition shall also be included in case double acting piston type actuator is selected. In either case, actuator shall be able to withstand maximum shut-off pressure with the minimum instrument air pressure specified.
9.14
Valve positioners wherever used shall be side mounted force balance pneumatic type. For electronic instrumentation, I/P converter shall be used along with pneumatic positioners. Separate air filter regulator shall be used for each valve positioner.
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Whenever limit switches are specified as inductive proximity type, these shall meet NAMUR (DIN-19234) requirements.
9.16
Solenoid valves, wherever used shall be universal type and continuous rated type with class F coil insulation as per 1EC 85 IS 1271. These shall be brass body with SS316 trim, as a minimum.
10.0
Pressure Relief Valves And Rupture Discs :
10.1
Pressure Relief Valves
10.2
All pressure relieving devices shall be designed in accordance with ASME code for 'Boilers and Pressure Vessels', API-521 and Indian Boiler Regulations.
10.3
Pressure relief valves shall be full nozzle full lift type except for thermal relief valves.
10.4
Conventional valves shall be specified for constant back pressure while bellows seal type valves shall be specified for variable back pressure more than 10% of set pressure. Pilot operated pressure relief valves shall be used for special services and where set pressure is closer than 10% of the operating pressure, in general.
10.5
Lifting lever shall be specified for steam and air service. Open bonnet shall be used for steam service.
10.6
3/4" x 1" threaded (NPT) modified nozzle type valves with typically 0.38 cm2 orifice size shall be specified for thermal relief.
10.7
The body material shall, as a minimum, be as per piping specifications. Nozzle and disc material shall be SS316 as a minimum with machined stainless steel guide and spindle. Whenever semi nozzle designs are unavoidable, body material shall be at least same as nozzle material.
10.8
The spring material of pressure relief valves shall be as follows unless otherwise necessary because of process conditions ;
10.9
-29°C to 250°C :
Cadmium/ Nickel plated carbon steel.
above 250°C
:
Tungsten alloy steel.
below - 29°C
:
Stainless steel 316
Flanged connection shall be for standard sizes 1" or larger. Minimum flange rating shall be 150 pounds ANSI.
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INSTALLATION & COMMISSIONING OF INTRUMENTATION SYSTEMS
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1.0
INSTALLATION MATERIALS
1.1
Vendor shall ensure and supply al l erection
hardware
required lor the
in s tallation of complete instrumentation which form a part of the package unit. This includes items like cables, cable glands, junction boxes, instrument valves and manifolds, mounting accessories, in pulse piping/tubing, pipe/tube fittings, pneumatic signal tubes, air line pipes and fittings, filter regulators, steam/electrical tracing, insulation materials, cable duct and trays, conduits, identification tags, structural material required for instrument supports and trays etc. 1.2
Clause 1.1 above broadly covers the items required for any typical plant, however the vendor shall supply all necessary items to make the installation and commissioning work complete in all respects, irrespective of whether these have been explicitly included in their scope or not.
1.3
Salient features and minimum requirements for some of the main installation materials is being described in the following paragraphs. For items for which no specification have been provided, vendor may follow their own specifications and prevailing international standards.
1.4
Cables
1.4.1
All cables shall have PVC insulated primary insulation of 85°C PVC as per IS-5831 Type C and inner and outer jacket shall be 90°C PVC to IS-5831 Type ST-2. Oxygen index of PVC shall be over 30% and temperature index shall be over 250°C.
1.4.2
When cables are required to be fire retardant, they shall be as per standard IEC 332 Part III Cat.A.
1.4.3
The insulation grade shall be 600 V/1100 V as a minimum and shall meet insulation resistance, voltage and spark test requirements as per BS-5308 Part-II.
1.4.4
All cables shall be twisted and armoured. Armour over inner jacket shall be of galvanised steel wire/flat as per IS-1554 part I.
1.4.5
For signal and control cables, inner jacket colour shall be black. Outer jacket colour shall be light blue for intrinsically safe application and black for others. For thermocouple extension cables the inner and outer jacket colour shall be as per IS8784.
1.4.6
Maximum dc resistance of the conductor of the completed cable shall not exceed the following :a)
12.3 ohms/km at 20°C for cables with 1.5 mm2 conductor.
b)
39.7 ohms/km at 20°C for cables with 0.5 mm2 conductor.
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1.4.7
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ADDITIONAL LIQUID PITCH HANDLING SYSTEM
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The mutual capacitance of the pair or adjacent cores shall not exceed 250 pF/m at a frequency of 1 kHz. The capacitance between any core and screen shall not exceed 400 pF/m at a frequency of 1 kHz.
1.4.8
L/ R ratio of adjacent cores shall not exceed 40 micro Henry/ ohms for cables with 1. 5 mm-conductor and 25 uH /Ohm for cables w i t h 0.5 mm2 conductor
1.4.9
The drain wire resistance in cluding shield shall not exceed 30 ohms/km.
1.4.10
A pair of communication wire shall be provided for multipair cables. Each wire shall be 0.5 mm2 of plain annealed single or multi-strand copper conductor with 0.4 mm thick 85°C PVC insulation. Insulation shall be green and red colour coded.
1.4.11
Vendor shall ensure a minimum of 20% of quantity of each type of cables supplied as spare including any special cable. And in each multipair cables 20% pairs shall be kept as spare.
1.4.12
Running length of the cable shall be printed at least at every 5 metre interval.
1.4.13
Make of signal/control/power cables: LAPP Cable/ Finolex/ Polycab/ AMP.
1.4.14
Signal Cables a)
Single pair shielded signal/alarm cables shall be used between field instruments/ switches and junction boxes/local control panels.
b)
Multipair individually and overall shielded signal/alarm cables shall be used between junction boxes/local control panels and control room, in general.
c)
The single pair/triad cables shall be 1.5 mm2 conductor size made of electrolytic copper conductor of 7 strands with each strand of 0.53 mm diameter, multipair cables with 0.5 mm2 conductor size shall have 16 strands of annealed electrolytic grade copper conductor with each strand of 0.2 mm diameter, multi triad cable or multi pair cable with 1.5 mm conductor shall have 7 strand with each strand of 0.53 mm diameter.
d)
Shield shall be aluminium backed mylar/polyester tape bonded together with the metallic side down helically applied with either side having 25% overlap and 100% coverage. The minimum shield thickness shall be 0.05 mm in case of single pair/traid and 0.075 mm incase of multipair/triad cable.
e)
Drain wire shall be provided for individual pair and overall shield which shall be 0.5 mm2 multi stranded bare tinned annealed copper conductor. The drain wire shall be in continuous contact with aluminium side of the shield.
f)
All multi pair cables shall have 6 pair/12 pairs only while multitriad cable shall have 6 triads/8 triads only.
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1.4.14 Control Cables a)
Single pair control cables shall be used between field mounted solenoid valves and junction boxes/local control panels and shall meet the requirements specified in para 1.4.13 above.
b)
Multipair control cables shall be used between junction boxes/local control panel and control room mounted devices in general. These cables shall have only overall shielding.
c)
These control cables shall have 1.5 sq mm conductor size with 7 stranded conductors of annealed electrolytic grade copper, with each strand of 0.53 mm diameter.
1.4.15 Thermocouple Extension Cables a)
Single pair shielded thermocouple extension cables shall be ured between thermocouple head and junction boxes transmitters/local control pane! mounted instruments.
b)
Multipair individually and overall shielded thermocouple extension cables shall be used between junction boxes and control room mounted devices.
c)
The type of thermocouple extension cables shall be compatible with' thermocciple used. In addition the colour coding of the primary insulation shall be as per IS-8784-1987 Table 5.
d)
The cable shall have 16 AWG and 20AWG solid conductors for single and multipairs respectively.
e)
All thermocouple extension cable shall be matched and calibrated in accordance with IEC-584-2.
f)
Shield shall be aluminium backed by mylar/polyester tape bonded together helically applied with the metallic side down with either side having 25% overlap and 100% surface. Minimum shield thickness shall be 0.05 mm for single pair and 0.075 mm for multipair cable. Drain wire shall be 0.5 mm: multistrand bare tinned annealed copper conductor. The drain wire shall be in continuous contact with the aluminium side of the shield.
g)
Inductance shall not exceed 4mH/Km.
h)
All multi-pair cables shall have 6 pairs/12 pairs only.
1.4.16 Power Supply and Other Cables a)
All power supply cables shall be as per IS-1554 Part I and shall have copper/aluminium conductors depending on conductor size. Minimum conductor size shall be 2.5 mm2 of copper conductor. For higher sizes, aluminium conductor can be considered. All these cables shall be PVC insulated and armoured.
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b)
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Any other special cable required for instruments shall also be supplied as per requirements. Vendor shall ensure that these cables are armoured type and shall meet all other requirements specified in para 1.4.1 through 1.4.12, as applicable.
1.5
Cable Glands a) Vendor shall supply all cable glands required for glanding the above mentioned cables both at field instrument and local control panel side, junction boxes side and at control room side. . b) All cable glands shall be Nickel plated Brass and they shall be double compression type suitable for armoured cables.
1.6
c)
Flame proof glands wherever required shall be supplied with Ex(d) certification.
d)
Vendor shall supply a minimum of 20% of cabie glands as spare.
Junction Boxes a)
Vendor shall supply junction boxes as per me cables selected wherever required. These shall be of die cast Aluminium alloy (LM-6) body and shall be weather proof. as a minimum.
b)
These boxes shall have terminals suitable for minimum or 4mm2 or less cable termination mounted on rails. 20% spare termini shall be supplied in each junction box.
c)
Flame proof junction boxes wherever required shall be supplied with Ex(d) certification. All such boxes shall be weatherproof also.
d)
Each junction box shall have a minimum of 10% or 2 Nos.. whichever is higher. spare entries. All spare entries shall be provided with plugs.
1.7
Instrument Connections
1.7.1
The connections of instruments installed on vessels, tanks, standpipes and piping shall be as per Annexures 1 & 2.
1.7.2
Pneumatic instrument connections for signal and ai r supply shall be 14" N'PT(F).
1.7.3 End connections shall meet the following, unless. otherwise specified: a)
Threaded end connection shall be NPT as per ANSI/ASME B 1.20.1.
b)
Flanged end connection shall be as per ANSI/ASME B 16.5. Flange face finish shall be per paragraphs 6.4.4.1, 6.4.4.2 and 6.4.4.3 of ANSI/ ASME B 16.5.
c)
Grooves of ring type joint flanges shall be octagonal as per ANSI/ASME B 16.20
1.8 1.8.1
Interface with Main Control Room Wherever applicable, instrument junction boxes shall be provided as interface.
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Marshalling details between purchaser-vendor tubing and cabling shall be shown with corresponding junction box termination number allocated against appropriate purchaser's/vendor's instrument tag number. Drawing shall be furnished separately for wiring and tubing for showing all instrument interface details. 1.8.2 Direct signals from package/ package skid a)
All signals from package/package skid to purchaser's remote control room/MCC shall be terminated in the junctions boxes located at the battery limit. Separate junction boxes shall be used for the following type of signals:
b)
•
Digital Inputs/Outputs (4-20mA)
•
Analog Inputs/Outputs (4-20 mA)
•
Thermocouple Inputs
•
RTD Inputs
•
Contact Inputs/Outputs
Intrimsically Safe barriers shall be part of the control system to which these inputs/outputs are connected.
1.9
Instrument Valves And Manifolds a)
Vendor shall supply instrument valves (miniature type) and valve manifolds wherever required.
b)
Body rating shall be as per piping class or better. However trim material shall be SS304, as a minimum. All valves and manifolds shall be forged type only.
c)
Valve body and trim material shall be 316 SS unless otherwise specified. Superior trim material shall be selected as required by process conditions. Packing material in general shall be of PTFE.
d) 1.10
Vendor shall supply a minimum of 20% instrument valves and manifolds as spare.
Impulse Piping/Tubing a)
Vendor shall supply 1/2" OD x 0.065" thick ASTM A 269 TP 316 stainless steel seamless tubes as a minimum for impulse lines.
b)
Where the pressure (operating) exceeds 70kg/cm2g or if piping is specified as impulse line, seamless pipes of size 1/2'NB of required thickness shall be supplied with material as per piping class.
1.11
c)
Seamless tubes shall have a hardness of max 80 RB as typical.
d)
Steam tracing shall be 10 mm OD copper tubes of electrolytic grade copper.
e)
Vendor shall supply a minimum of 20% of pipe/tubes as spare.
Pipes and tube fittings a)
Vendor shall supply flare less compression type of tube fitting and or three niece
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construction with design similar to swage Lock/Parker Hannifen Ermeto etc. b)
The fitting/ferrule hardness shall be in the range of RB 85-90 so as to ensure a minimum hardness difference of 5 to 10 between tube and fittings. The ferrule shall be of stainless steel material, in general.
c)
Socket-weld type forged pipe fittings of suitable material and rating shall be supplied for pipe fittings. The minimum rating shall be 3000 lbs. Weld neck fittings shall be used where socket weld type are not allowed by piping class.
d)
Instrument air brass fittings shall be suitable for use on copper tubes conforming to ASTM B 68/B 68 M hardness not exceeding RB 50. All fitting parts shall be manufactured from Brass as per IS-319 bar stock or equivalent and shall be nickel plated.
e)
All threaded fittings shall have NPT threads as per ANSI/ASME B16.11 only.
f)
Vendor shall supply a minimum of 20% of each type of pipe/tube fittings as spare.
1.10
Pneumatic Signal Tubes a)
Vendor shall supply 6rnm OD x 1mm thick PVC covered fully annealed electrolytic grade copper tubes as per ASTM B68.74A Cu. No. 122 (DH) for pneumatic signal tubes.
b)
Vendor shall avoid use of intermediate connections and shall estimate single length for each instrument location.
c) 1.11
Vendor shall supply a minimum of 20% length of these tubes as spares.
Instrument Air Lines Fittings And Valves a)
Seamless galvanised, inside and outside, carbon steel pipes used for instrument air distribution shall be as per IS 1239 class Heavy.
b)
Galvanised forged screwed carbon steel screwed fittings of 2000 lbs rating fittings shall be used.
c)
Isolation valves on instrument air service shall be packless gland type full bore ball valves.
d) 1.12
Vendor shall supply a minimum of 20% of air pipe, fittings and valves as spare.
Air Filter Regulators a)
Instrument air filter regulator of suitable size, range and capacity shall be supplied for each pneumatic instrument.
b)
The body of the filter shall be anodised aluminium.
c)
The filter shall have 5 micron sintered bronze/ceramic filter element and shall be provided with manual drain and 2" nominal size pressure gauge.
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1.13
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Trays and Cable Ducts All cables on the main pipe rack shall be laid in cable duct. Cable ducts shall be
a)
fabricated as per 'Duct Fabrication Details' standard No. 7-52-253. b)
All branch cables/tubes shall run on cable trays.
c)
These cable trays shall be made out of galvanised mild steel sheets of 2.5 mm thickness. Ladder trays shall be of mild structural steel and shall be painted with red-oxide primer. 50 mm x 50 mm angle shall be used as a minimum.
d)
The width shall be so selected that 50% of tray space is available for future use.
e)
Suitable cable clamps shall be supplied for binding the cables/tubes at every 500 mm.
1.14
Instrument Support/Structural Steel Vendor shall supply instrument stands, stancheons and other structural steel material required for supporting the cable trays, impulse lines and instruments.
2.0
GUIDELINES FOR INSTALLATION INSTRUMENTS AND CONTROL SYSTEM
2.1
Vendor shall be completely responsible for installation of all instruments within their battery limit, in line with the installation standards (typical) furnished along with this specification.
2.2
Whenever installation is beyond the scope of vendor/contractor, purchaser shall install the
instruments
as
per
the
details/documents/drawings
provided
by
the
vendor/contractor. However, in such a case it must be ensured that complete installation materials shall be supplied. 2.3
All direct mounted instruments like thermocouples thermoweils, temperature gauges, pressure gauges, pressure switches etc. shall be installed in such a way that they have good readability and accessibility.
2.4
The capillary of all capillary type instruments shall be supported properly and shall be protected against mechanical damage.
2.5
All pressure/differential pressure instruments shall be provided with block and bleed/bypass, drain/vent valves etc as per the installation standards, and shall have accessibility.
2.6
All primary piping/tubing (impulse lines) shall have a slope of 1 in 12 on the horizontal run.
2.7
All welding shall be carried out as per the relevant codes with proper electrodes. Any testing (non destructive) like D.P. test and radiography on root weld and final weld shall be carried out as applicable. All consumables shall be part of vendor's scope of supply. Any pre/post weld treatment as required by the relevant codes shall be
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carried out. 2.8
All threaded joints shall be joined by PTFE tapes only.
2.9
All impulse lines shall be supported at regular intervals.
2. 10
instrument drain/vent connections shall be piped to safe area like oiiy water sewer or above pipe racks to avoid accumulation of hazardous fluid in the plant atmosphere.
2.11
Steam tracing wherever required shall be carried out by 10 mm OD x 1 mm th i c k Copper tubes and condensate traps shall be provided to collect all the condensate and shall be piped to the nearest pipe drain funnels.
2.12
All tubes/cables shall be properly laid on cable trays which shall be supported at regular intervals.
2.13
Separate routing or physical separation shall be maintained between signal cables, shut down and power cables.
2.14
Wherever intrinsically safe system cabling is employed, the minimum separation of 150 mm shall be adhered between IS (intrinsically safe) and non IS signal cables.
2.15
The cases of instruments shall be earthed by earthing wire to the nearest earth bus bar for safety reasons.
2.16
In case the cables are to be buried or laid in concrete trench the same shall be carried out by vendor. In case civil work is carried out by purchaser, requirement of trenches shall be provided with prior intimation to client.
2.17
Painting of cable trays/ducts, mild steel cable trays, angle trays, instrument supports and all structural supports shall be painted as under :a) The surface to be painted shall be thoroughly cleaned with brush sand paper to remove all scales. After cleaning, one coat of red oxide zinc chromate primer shall be given conforming to IS-2074 and allowed to dry. One coat of final when paint shall be applied. b) Second and final coats of paint of final colour shall be given before handing over the plant/ commissioning.
2.15
All line or equipment mounted instruments like control valves, pressure r eli e f valves. thermowells, oritice flanges, level instruments etc., installed on pipes and vessels under IBR shall be certified by IBR or their authorised representative.
2.16
Location of process connections shall be from the side or from the top of the process equipment but not from the bottom. This requirement is applicable to both pipes and vessels. The location of lower side connection when necessary, shall be high enough to prevent plugging due to d i r t or other suspended solids. In addition, the connections shall be short, vertical or horizontal and without any pockets.
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2.17
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Vendor to ensure that the selected material is consistent with temperature, pressure, corrosion conditions and other process requirements. Incase where suitable material of construction is not feasible/possible, diaphragm seal shall be considered.
2.18
Installation of PLC/SLC Systems
2.18.1
The system shall be installed by the system vendor who would be responsible for installation and termination of interconnecting cables in the system racks/cabinets. All interconnecting cables shall be identified and the individual cores/wires shall be properly identified using ferrules. Direct-cross ferruling method shall be used for identification.
2.18.2
All system communication cables shall be layed in covered GI (galvenised iron) trays away from power cables. Prefabricated cables shall be avoided for interconnection if these are to be routed out side the cabinets. If unavoidable these should be laid in covered GI trays.
2.18.3
All panels/cabinets shall be properly levelled and secured firmly with the base supporting structure. However, the consoles and printer stands need not be secured to base structure.
2.19
Grounding a)
Each cabinet. console anc other equipment supplied as a pan or svstem shall have earthling lugs which shall be secured to the "AC mains earthing bus”.
b)
All circuit grounds, shields and drain wires shall be connected to the 'system ground' bus which is isolated from 'AC mains earth'. This bus shall ty pically be 25 mm wide and 6 mm thick of copper. The total resistance of system ground shall be less than 5 ohms unless otherwise recommended by system manufacturer.
c)
Safety barriers, if used, shall be secured to 'Safety ground' which shall have typically ground resistance of less than 1 ohm. The bus shall be designed considering a fault level of 0.5 A at 250V r.m.s. per barrier.
3.0
TESTING AND CALIBRATION
3.1
All instruments supplied by the vendor shall be calibrated using proper test equipment. The calibration certificates are to be submitted from NABL accreditated laboratory.
3.2
AIl instruments shall be calibrated for 0%.25%.50%.75%.100% and vice versa.
3.3
All temperature gauges shall be calibrated using temperature baths potentiometer.
3.4
All transmitters shall be calibrated as per instrument ranges.
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3.5
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All displacer type level transmitters shall be calibrated with water or suitable fluids and corrected for specific gravity.
3.6
All alarm and trip switches shall be calibrated over the entire range and finally set and checked for alarm/trip points and reset points as per the alarm/trip set point schedule after setting, these shall be sealed.
3.7
All electronic/pneumatic receiver instruments shall be calibrated as per the manufacturer's instructions. Controllers shall be aligned properly.
3.8
The accuracy of overall loop shall be within +/- 1 % for electronic and +/- 1.5 % for pneumatic loops.
3.9
After performing the calibration of all instruments, the entire loop shall be checked for proper operation.
3.10
All instrument cables shall be tested for continuity and insulation. While meggering the cables for insulation testing, ensure that all instruments and barriers are isolated at both ends.
3.11
The entire shutdown scheme shall be simulated from the process trip switches and the scheme shall be tested for its proper operation prior to start up of the unit.
3.12
If no instrument air is available vendor shall provide necessary N2 cylinders to carry out the above activity.
3.13
Testing of PC-PLC Systems :
3.13.1 All the system functions shall be checked thoroughly for proper functioning. These shall include but not limited to the following tests : a) Visual and mechanical, b) Complete system configuration loading. c) Demonstration of all system functions. d) Checking of all systems displays. e) Checking of correct functioning of all keyboards. f) Demonstration of all system diagnostics. g) Checking of proper functioning of all printers. hardcopy unit. and printing of all reports. h) Checking of all disc drives. i) Complete checking of logic system. loadin6 of user's program and checkout of results. j) Checking of correct change-over of the back-up/redundant units in case of failure of main units.
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3.13.2 The input signals shall be simulated by disconnecting the field wires for all inputs. Wherever control room mounted Transmitters/Converters/Receiver switches are used, the functioning of same shall also be checked. 3.14
Loop Checking
3.14.1 Loop checking shall be carried out by vendor which shall include proper functioning and interconnection of all items in the loop. 3.14.2 All input signals shall be generated in the field and corresponding reading shall be checked at all corresponding displays. All the outputs shall be checked in the field by physical verification of valve stroke or operation of solenoid valve/pick-up of electrical contactor. 3.14.3 After loop checking is completed vendor shall connect back any terminals and connections removed during loop checking.
4.0
COMMISSIONING
4.1
This activity shall be carried out in a systematic manner so as to avoid any accident to plant and operating personnel.
4.2
During the plant start up all the instruments calibration, controller alignment, trip point settings shall be trimmed so as to meet the operation requirements.
4.3
Prior to guarantee run of any package unit the vital instruments as required by vendor have to be recalibrated and the results recorded.
4.4
After the successful commissioning of equipments the entire control system shall be put on trial run test on actual site conditions as per standard test procedure.
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SPECIFICATION FOR MECHANICAL COMPONENTS
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TECHNICAL SPECIFICATION FOR BASKET FILTER
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C O N T E N T S
1.
SCOPE
2-
CODES AND STANDARDS
3
-
TECHNICAL REQUIREMENTS
4
-
INSPECTION AND TESTING
5-
PROTECTION AND PAINTING
6.
PACKAGING AND IDENTIFICATION
7.
SPARE PARTS
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1.0 1.1
OVERALL PAGE
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SCOPE This specification defines the minimum requirements according to which the manufacturer shall design, manufacture, test and supply the Basket Filter for removing solid contaminants from the liquid stream.
2.0 2.1
PROJECT TITLE
ADDITIONAL LIQUID PITCH HANDLING SYSTEM
CODES AND STANDARDS Following codes & standards (latest edition) shall be followed for design, fabrication, testing etc. of the equipment. ASME SEC.VIII DIV. I : Boiler and Pressure Vessel Code. ASME SEC. IX
: Welding and Brazing Qualifications.
ASME SEC. II & ASTM
: Material specifications.
ANSI B 16.5
: Pipe flanges & pipe fittings.
ANSI B 16.11
: Forged steel fittings socket welded & threaded.
ANSI B 36.10
: Welding & seamless wrought steel pipe.
2.2
For purposes of material selection national code of the country of origin shall also be acceptable provided the vendor specifically establishes, to the satisfaction of the purchaser, the equivalence or superiority of the proposed material with respect to those specified.
3.
TECHNICAL REQUIREMENTS
3.1
The equipment shall be of the type as mentioned in the data sheets and shall meet the duty requirements and performance parameters as mentioned therein.
3.2
Vendor shall submit process design calculations for sizing of the equipment together with all supporting documents/catalogues/nomographs etc. with the bid. It shall be clearly indicated how the basket size has been arrived at for each equipment.
3.3
Free area of basket shall be minimum 8 times of the inlet nozzle area. Gross area shall be calculated based on the required free area and the % free area, and it shall not be less than 20 times of the inlet nozzle area. Bidder shall furnish the actual gross/free area and the volume of basket. Basket shall be of straight cylindrical shape. Suitable baffle plates shall be provided in the vessels for proper fluid flow distribution. Vessel diameter shall be minimum twice the diameter of inlet nozzle.
3.4
3.5
Corrosion allowance of 3mm shall be considered for all carbon steel parts, unless otherwise mentioned in the data sheets.
3.6
Vessels of diameters 300NB & below shall be made from seamless pipe only. For bigger diameters, shell shall be fabricated by rolling the plates lengthwise and specified radiography and appropriate welding procedures shall be followed.
3.7
In case the vendor's fabrication shop is not NALCO approved for the thickness of vessel involved, the vendor shall either (i) get the vessel fabricated by an outside NALCO approved vendor or (ii) get the vessel rolled by one of the NALCO approved vendor and get the fabrication done at his own shop.
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3.8
Dished ends shall be of seamless construction, tori-spherical or 2:1 ellipsoidal type and shall be heat-treated after forming as per ASME Sec. VIII Div.l.
3.9
All nozzles/pipes on the vessel shall be of seamless construction. All nozzles less than or equal to 2" NB size shall be provided with 2 Nos, 6mm thick stiffeners at 90 degree to each other. All nozzles above 3" NB size, shall be provided with reinforcement pads. Calculations for reinforcement pads as per ASME shall be submitted for purchaser's approval.
3.10 All flanges upto 150 rating shall be of weld neck type (for sizes upto 100 NB) or slipon type forged steel to ANSI (for sizes above 100NB. All flanges above 150 rating shall be weld neck type only irrespective of the nozzle size. All flanges shall be raised face type, with serrated finish unless specified otherwise. 3.11 Dimensions of flanges including shell flanges, blind head cover flanges, nozzle flanges and blind flanges shall be as per ANSI B 16.5. Larger flanges not covered by ANSI shall be as per MSS-SP-44. 3.12 Swing bolt with pin arrangement shall be provided for the top cover, unless otherwise specified in the Data Sheet. The swing bolts shall be of one piece construction without welding. Hinge Pins shall be solid (not rolled) and of the same material as the swing bolts. Suitable no. of dowel Pins shall be provided for proper location of the top cover. The top cover shall be a flat forged blind flange in this case. Top cover weighing more than 15 kg shall be provided with lifting davit. 3.13
Drain and vent connections shall be provided with matching blind cover flanges along with necessary gaskets, nuts and bolts.
3.14
Pressure parts joined by butt welds shall be with full penetration, welds, Where both sides welding is not accessible, root run by tungsten inert gas process or backing strip, shall be used to ensure full penetration. Backing strip if used, shall be removed after welding.
3.15
Vessels shall be post weld heat treated, whenever it is required due to service requirement or due to code requirements. Vessels shall be post weld heat treated, as a complete unit and no welding shall be permitted after the post weld heat treatment is completed.
4.0
INSPECTION AND TESTING
4.1
4.2
Equipment shall be subjected to stage wise, inspection and testing at vendor's/sub vendor’s works by purchaser/its authorized inspection agency. Vendor shall submit Quality Assurance (QA) Procedures before commencement of fabrication. Approved QA procedures shall form the basis for equipment inspection. Testing at vendor's works shall include but not limited to the following: -
Non-destructive tests such as radiography, dye penetration tests. Hydrostatic test at 150% of design pressure for the vessel.
4.3
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Any other tests as per data sheets/standards/ codes.
Any or all the tests, at purchaser's option, shall be witnessed by Purchaser/its authorized inspection agency. However, such inspection shall be regarded as check up and in no way absolve the vendor of his responsibility. DOCUMENT TITLE
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5.0
PROTECTION AND PAINTING
5.1
All exposed carbon steel parts to be painted shall be thoroughly cleaned to remove scale, rust, dirt and other foreign materials by wire brushing and sand blasting as applicable. Minimum acceptable standard in case of power tool cleaning shall be St3 and in case of blast cleaning shall be Sa 2 1/2 as per Swedish standard SIS 055900-1967.
5.2
Non-ferrous materials, austenitic stainless steels, plastic or plastic coated materials, insulated surface of equipment and pre-painted items shall not be painted.
5.3
Stainless steel surface, both inside and outside, shall be pickled and passivated.
5.4
Machined and bearing surface shall be protected with varnish or thick coat of grease.
5.5
Depending on the environment, following primer and finish coats shall be applied: Environment i) Normal industrial
Paint System Primer
: 2 coats of red oxide zinc chromate, each 25 microns (min.) thick. Finish : 2 coats of synthetic ena-coat enamel, each 25 microns (min.) thick.
ii)
Corrosive Industrial
Primer
: 2 coats of epoxy zinc chromate, each 3 5 microns (min.)thick. Finish : 2 coats of epoxy high coat build paint, each 100 microns (min.)thick.
iii)
Coastal and marine
Primer
Finish coat
: 2 coats of high build chlorinated rubber zinc phosphate, each 50 microns (min.)thick. : 2 coats of chlorinated Rubber paint, each 3 5 microns (min.) thick. (All values refer to dry film thickness).
5.6
The colour of finish coat vendor after placement of order.
6.0
PACKAGING AND IDENTIFICATION
6.1
All packaging shall be done in such a manner as to reduce the volume. The equipment shall be dismantled into major components, suitable for shipment and shall be properly packed to provide adequate protection during shipment. All assemblies shall be properly match marked for site erection.
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shall
be
intimated
to
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6.2
Accessories, spare parts of the equipment and small items shall be packed separately in wooden-cases. Each item shall be appropriately tagged with identification of main equipment, item denomination and reference number of the respective assembly drawing.
6.3
Detailed packing list in waterproof envelope shall be inserted in the package together with equipment.
6.4
Each equipment shall have an identification plate giving salient equipment data, make, year of manufacture, equipment number, name of manufacturer etc.
7.0
SPARE PARTS
7.1
Vendor shall submit recommended list of spare parts with recommended quantities and itemized prices for first two years of operation of the equipment. Proper coding and referencing of spare parts shall be done so that later identification with appropriate equipment will be facilitated.
7.2
Recommended spares shall be limited to basket(s) and gasket(s) only.
7.3
Vendor shall also submit a list of recommended commissioning spares with quantities as a part of main offer.
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STANDARD SPECIFICATION FOR POSITIVE DISPLACEMENT PUMPS-ROTARY
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SPECIFICATION OF INTERNAL JACKETED GEAR PUMP FOR PITCH:
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Pumping fluid: Coal Tar Pitch Temp.: 150-160 degree Celsius Viscosity (mPass): 3000-7500 Capcity: 30 M3/ Hour Differential Pressure (Bar): 5-5.80 Specific Gravity of Pitch: 1.18-1.25 Suction Pressure (bar g): (-) 0.410 Volumetric efficiency: 95 .30 % Mechanical efficiency: 71 % Nozzle: ANSI CL 300 Casing Mounting: Horizontal Drains: 04 Nos. Maximum allowable pressure: 20 Bar Hydrostatic test pressure: 30 Bar Thermic Fluid Jacket Pressure: 12 Bar Rotor Mount: Overhung Relief Vale: Built in, Cast Steel Thermic Fluid Jacketing: front cover, Stuffing Box & relief Valve Bearing Type: Antifriction thrust bearing Bearings Mounting – Horizontal Lubrication: Grease Pump Casing: Nodular Cast iron Rotor: Cast Steel Shaft: Steel nitrided Shaft Seal: Graphite/ PTFE Mechanical Seal as per DIN 24960 Bearing Housing: Cast iron Gland: Stainless steel Base Plate : MS Certificate of compliance s per EN 10204
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STANDARD SPECIFICATION FOR CENTRIFUGAL PUMPS
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SCOPE
i.
This specification together with the attendant Data Sheets and other specifications/attachments to inquiry / order defines the minimum requirements for vertical and horizontal centrifugal pumps including pumps and their accessories / auxiliaries for use in the process and pipeline applications.
ii.
Vendor shall make all possible efforts to comply strictly with the requirements of this specification and other specifications/attachments to inquiry/order. In case deviations are considered essential by the vendor (after exhausting all possible efforts) these shall be separately listed in the vendor's proposal under separate section titled as "List of deviations/exceptions to the inquiry document". Deviation shall be listed separately for each document with cross-reference to Page No./Section/Clause No./Para etc. of the respective document supported with proper reasons for the deviation for purchaser's consideration. Any deviation not listed under the above section, even if reflected in any other portion of the proposal shall not be considered applicable. No deviation or exception shall be permitted without the written approval of the purchaser.
iii
Compliance with this specification shall not relieve the vendor of the responsibility of furnishing equipment and accessories/auxiliaries of proper design, materials and workmanship to meet the specified start up and operating conditions. In case the vendor considers requirement of additional instrumentation, controls, safety devices and any other accessories/auxiliaries essential for safe and satisfactory operation of the equipment, he shall recommend the same along with reasons in a separate section along with his proposal and include the same in his scope of supply.
iv)
1.1
Except as modified herein, the centrifugal pumps shall be designed, manufactured, tested and supplied strictly in accordance with the API Standard 610 - Centrifugal Pumps for General Refinery Service, Sixth Edition, January 1981.
EQUIPMENT QUALIFICATION CRITERIA
1.1.1 Unless otherwise specified elsewhere, the Equipment Qualification Criteria (EQC) specified vide para 1.1.2 to 1.1.4 of this specification shall be applied for acceptance of the offered pump model. 1.1.2 The pump vendor shall be an established centrifugal pump manufacturer having adequate engineering, manufacturing and testing facilities for pumps conforming to API Standard. 1.1.3 The pump model offered shall be from the existing regular manufacturing range of the pump manufacturer. The mechanical as well as the hydraulic performance (including NPSHR) for the complete range of operation of the offered model shall have been established in the shop
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test. The offered pump model shall meet the following minimum service and manufacturing experience requirements. Pumps shall be identical or validly similar in terms of Power rating, Hydraulic Performance (including NPSHR), Inlet flow, Differential Head, Operating Pressure & Temperature, Pumping Liquid, Speed, Number & Type of Impellers, Mechanical Design, Materials, Bearing span (applicable for between bearing pumps), Column Length (applicable for vertically suspended pumps) etc. as compared to at least TWO UNITS of the proposed model designed, manufactured, tested and supplied from the proposed manufacturing plant in the last fifteen years and at least ONE of these units shall have successfully operated in the field for at least 8000 hours individually without any major overhaul as on the date of issue of inquiry. 1.1.4
In case the vendor is a licensee and does not meet on his own the above criteria as per 1.1.3, the vendor can substitute the references of his Collaborator (licensor) provided the following conditions are met by the vendor.
1.1.4.1 The vendor shall be regular & established manufacturer of centrifugal pump and shall have supplied several smaller & larger sizes of pumps from the proposed manufacturingplant and proves to the satisfaction of the purchaser that the vendor does possess the manufacturing & testing facilities for the offered pump. 1.1.4.2 Vendor's Collaborator (licensor) meets the criteria as per 1.1.3. 1.1.4.3 Vendor's license agreement is valid and continues to remain valid till, atleast TWO years after the delivery of the pumps. 1.1.4.4 The vendor imports as a minimum the following critical components from his Collaborator (licensor)/Collaborator’s sub-vendors. Impellers/Diffusers (fully machined) Complete Rotor Assembly (dynamically balanced) for multi-stage pumps Casing (proof machined, hydrostatically tested) Bearing Bracket (unless it is common to other pumps and has been manufactured by the vendor as a regular item). 1.1.5 As an alternate to para 1.1.4.4 above, pump vendor may develop these items indigenously, provided the vendor undertakes to offer the proposed pump for performance test within five months of LOI/FOI and furnishes an undertaking that in case the performance test of indigenously developed pumps is not within the specified acceptance limits, the vendor shall import the components defined under para 1.1.4.4 above at no extra cost and delivery implications to the purchaser. 1.1.6
Pump vendor shall indicate the details of such arrangement in the proposal.
1.1.7
PROVEN TRACK RECORD (PTR) Pump Vendor shall complete the Experience Record Proforma's enclosed with the inquiry document to amply prove that the offered pumps meet the EQC for technical acceptance. Special attention is drawn to applications involving high suction pressure, high/low operating temperature and low NPSHR. Vendor shall also identify the imported components against each specific reference in the PTR. Vendor may furnish
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additional information to justify that the EQC is being met. In addition, manufacturer's catalogue and general reference list for Centrifugal Pumps shall also be furnished along with the proposal. SECTION 2 - BASIC DESIGN 2.1
GENERAL
2.1.2
(Substitution) Horizontal pumps of the close-coupled, two stages overhung, multi stage ring section, or the single stage double suction overhung, type shall not be furnished.
2.1.4
(Addition) Pumps where difference between NPSHA and NPSHR from quoted minimum flow to rated flow is less than 0.6 meter are not acceptable. The said NPSHR value shall correspond to the maximum value of NPSHR from rated flow down to the recommended minimum continuous stable flow specified by the vendor.
Pumps fitted with inducers for reducing NPSHR are not acceptable. 2.1.6
(Modification) Refer Performance Correction Chart of Hydraulic Institute Standard. Correction factors as applicable shall be indicated by the manufacturer on the filled-in data sheet.
2.1.8
(Substitution) The best efficiency point for the furnished impeller is preferred between the rated point and the normal point. However in no case the rated point shall be beyond 110% of the best efficiency point of the rated impeller.
2.1.9
(Substitution) The maximum permissible sound level shall not exceed 88 dBA measured at 1 meter from pump surface for the recommended range of operation.
2.1.11
(Modification) For vertical pumps, not provided with non-reverse ratchet vendor shall describe the precaution taken, to prevent damage due to reverse rotation.
2.1.15
(Addition) Piping shall extend upto the edge of base plate. Gate Valve shall be provided at the inlet line & Globe valve at the outlet.
2.1.16
(Modification) Maximum inlet temperature 33°C, maximum temperature rise 17°C, fouling factor water side 0.0004 m2h°C/kcal, maximum allowable working pressure 8 kg/cm2g.
2.1.19
(Modification) Unless otherwise specified, equipment will be designed to be suitable for outdoor installation without a roof.
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2.1.21
(New) For balancing axial thrust in Multistage pumps only the following arrangements shall be used either singly or in combination Opposed arrangement of impeller A balancing piston
2.2
PRESSURE CASINGS
2.2.2
(Modification) Areas of double casing and horizontal multistage (3 or more stages) pumps as well as suction can of vertical canned pumps shall also be designed for discharge pressure.
2.2.3
Deleted.
2.2.9
(Substitution) Centerline supported pump casings shall be used for horizontal pumps.
2.2.11
(New) Casings of inline pumps shall be split perpendicular to the shaft and shall not require rigid support from the foundation. The design of inline pumps shall permit removal of the rotor without disconnecting the main piping.
2.3
NOZZLES & MISCELLANEOUS CONNECTIONS
2.3.1
(Modification) Flanged nozzle connections shall be offered for all sizes and all applications.
2.3.3
(Modification) Casing shall be provided with drain connection with nipple, threaded and seal welded and provided with a socket welded gate valve terminated at edge of the base plate. Gate valve shall be of 800# rating with material of construction (MOC) equal or superior to the pump casing. For multistage pumps with more than one drain point, block valves at each drain point shall be provided and the piping shall be terminated at edge of the base plate with a flange. Unless made self venting design, vent connections shall also be provided with a nipple, threaded and seal welded and terminated with a gate valve. Pressure gauge connection shall not be provided unless specifically required in the inquiry.
2.3.6
Suction and Discharge Flanges and Facings
2.3.6.1
(Addition) In the event that nozzle sizes of 32 mm (1V* inch), 65 mm (2lA inch), 90 mm (3Vi inch), 125 mm (5 inch), 175 mm (7 inch) and 225 mm (9 inch) are offered, forged companion flanges (weld neck type) with nuts, bolts and gaskets shall be supplied along with pumps. The metallurgy of the companion flanges shall be same as casing metallurgy or superior.
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2.4
EXTERNAL NOZZLES FORCES & MOMENTS
2.4.7
(Modification) The vendor shall provide calculation and/or available supporting test data for shaft displacement at the coupling with forces and moments applied according to 2.4.3.
2.5
ROTATING ELEMENTS
2.5.1
(Modification) Fabricated impellers are not acceptable.
2.5.4
(Modification) Impellers for multi-stage pumps shall be individually secured against axial movement in either direction along the shaft.
2.6
WEAR RINGS
2.6.3 (Modification) Tack welding is not acceptable.
2.6.4.2
(Addition) Vendor shall also furnish in the proposal the maximum permissible running clearance, which in no case shall be less than twice the running clearances as specified in this clause.
2.7
SEAL
2.7.1.1
(Addition) The mechanical seal shall be of a make, duly approved by the purchaser.
2.7.1.2
(Modification) Only balanced type mechanical seal shall be furnished.
2.7.1.4
(Addition) In case vendor has any reservation to the flushing plans and/or seal material selection, the vendor shall submit alternate proposal supported by seal manufacturer's recommendation.
2.7.1.11
(Modification) Jackets shall be provided on pump seal chamber for any of the conditions and services specified in item 1 through 5 of this clause.
2.7.1.13 (Modification) Requirement of the throat bushing shall be decided by the vendor to suit the operating conditions unless otherwise specified in the data sheet. 2.7.2.7
(Modification) Pump packing shall be supplied duly installed on the pump.
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2.8
DYNAMICS
2.8.1.4
(Addition) This condition shall be satisfied for the entire range from the design running clearances upto the maximum permissible clearance as defined under clause 2.6.4.2.
2.8.2.1
(Addition) Impellers for all overhung design pumps shall be dynamically balanced in accordance with Gr. 2.5 as per ISO 1940. In case of between bearing pumps complete rotor assembly including coupling half shall be dynamically balanced to Gr. 2.5 as per ISO 1940.
2.8.2.2 (Addition) & 2.8.2.3 The above limits of vibration shall also be applicable for the maximum clearances specified in 2.6.4.2. 2.8.2.5
(Modification) The vendor shall demonstrate at his shop that the pump can operate at the quoted minimum continuous stable flow without exceeding the vibration limits given in 2.8.2.2 and 2.8.2.3.
2.9
BEARINGS & BEARING HOUSINGS
2.9.1.10
(Modification) The thrust collar shall be replaceable and shall be positively locked to the shaft to prevent fretting.
2.9.1.14
(Substitution) For pumps handling flammable or hazardous liquids, bearing housings, load carrying bearing housing covers, and brackets between the pump casing or head and the bearing housing shall be steel. Driver supports for vertical pumps which utilize thrust bearings in driver to support the shaft, shall be steel.
2.9.1.16
(Substitution) The vendor shall furnish oil heaters when ambient or operating temperature dictates.
2.9.1.18
(Addition & Modification) Jacketed bearing housing shall be provided for pumping fluid temperatures of 160°C and above. Cooling coils are not acceptable.
2.9.2.3
(New) i For self liquid lubricated pumps, guide bushing shall be suitable for dry running during start up.
2.9.2.4
(New) Bearing housing shall be equipped with magnetic drain plug.
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2.11
MATERIALS
2.11.1.1
(Modification) The material of construction of pump parts shall be in accordance with the data sheet.
2.11.1.7
(Substitution) Vendor shall furnish chemical and mechanical data for the parts as defined under clause 2.11.4
2.11.4.1
(Addition) As a minimum, the components of the pumps shall be subjected to following tests and the test certificates furnished to the Purchaser accordingly: a) Shaft, Impeller, Pressure Casing : Chemical Analysis and Tensile Test. b) Wearing rings, bushing and sleeve : Chemical Analysis and Hardness. c) In addition to above requirements for multistage pumps: i) Shaft material shall be subjected to ultrasonic testing for internal defects and magnetic particle test for surface/sub-surface defects and Dye pentrant tests on areas where chrome plating is required. ii) Pressure casing parts shall be subjected to magnetic particle test on unmachined surface and Dye pentrant tests on machined surfaces. For design temperatures as indicated in the data sheet below -29°C, materials shall be subjected to impact test to meet the requirement of 2.11.5, unless the materials are exempted in accordance with the requirements of Section VIII Div. I of ASME Code. For Carbon Steel construction pumps, in caustic services, the pressure containing components as well as any welding performed on these, shall be stress relieved.
2.12.2
(Modification) Rated capacity in m3/hr. Casing hydrostatic test pressure in kg/cm2 Differential head at rated capacity in m, Speed in r.p.m.
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SECTION 3 - ACCESSORIES 3.1
DRIVER
3.1.2
(Substitution) Electric motor drivers shall have a maximum continuous rating (MCR) (i.e. service factor equal to 1) not lower than the following unless higher rating is dictated by the Note 1 and/or Note 2. Motor Name plate Rating Motor MCR (% of Pump Rated BKW) Less than 22 kW : To suit maximum BKW indicated on pump data sheet or 125% of rated pump BKW, whichever is higher. 22 kW - 55 kW 115 % of rated pump BKW. Higher than 55 kW 110% of rated pump BKW.
Note : 1. The motor nameplate rating for pumps under parallel operation shall not be less than the max. BKW indicated on pump data sheet (Power at End of the curve for the rated impeller) or shall have the specified margin as per this clause whichever is greater. The pump motors shall also be suitable for start-up under open discharge valve condition. 2. The motor nameplate rating for applications where the specific gravity of pumped fluid is less than 1.0 shall either be 100% of the BKW of pump at minimum continuous stable flow with clean cold water of sp. gravity 1.0 or shall have tie specified margin as per this clause, whichever is greater. 3.1.4
(Addition) The complete co-ordination to achieve the above shall be the responsibility of the pump vendor.
3.1.10 (New) Gas Turbines and IC Engines shall comply with requirements of driver specifications of the Purchaser. 3.1.11
(New) The continuous rating of Gas Turbine/IC Engines at the specified site conditions shall not be less than 110% of pump rated BKW.
3.2
COUPLING & GUARDS
3.2.2
(Substitution) Coupling shall be of forged steel and of non-lubricated, laminated disc type, with stainless steel/monel laminations. The selected coupling shall have a service factor not less than 1.5 over driver nameplate rating. A spacer coupling (127mm minimum normal length) shall be used unless otherwise specified. The spacer length shall
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permit the removal of coupling, bearings, seal, and/or rotor, as applicable, without disturbing the pump casing/casing top covers of axial split casings, driver or the suction and discharge piping. It shall be the responsibility of the pump vendor to obtain Purchaser's approval for the selected coupling, its make and rating. 3.2.7
(Modification) Coupling shall be dynamically balanced in accordance with grade 2.5 as per ISO 1940 and a certificate to this effect shall be furnished.
3.2.8
(Substitution) Unless otherwise specified, couplings operating at speeds greater than 3000 rpm shall be as per API Standard 671.
3.2.12
(Modification) Whether or not pump vendor is required to mount the driver, he shall still deliver the fully machined coupling assembly along with the pump. The driver shaft dimensions and tolerances shall be furnished by the Purchaser to the pump vendor.
3.2.13
(Substitution) Removable coupling guard shall be provided which shall be fabricated from nonsparking material, and shall be open at the bottom to permit manual shaft rotation. The guard shall be sufficiently rigid to withstand deflections as a result of bodily contact of nominally 100 kgs.
3.3
MOUNTING PLATES
3.3.1.2
(Addition) The length shall be atleast equal to the overall length of the pump and motor assembly.
3.3.1.7
(Modification) Unless otherwise specified, base plate for all sizes of pump shall be grouted.
3.3.1.9
(Modification) For liquid temperature 260°C and above or when recommended by vendor, pedestals for centerline supported pumps, handling hot fluid shall be designed for supplemental cooling to maintain alignment.
3.3.1.11 (Modification) For pumps having driver rating 18.5 kW and above, leveling screws as specified in this clause shall be provided. 3.3.1.12 (Modification) Manufacturer's standard practice shall be followed. 3.3.1.14 (New)
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Pumps in corrosive service shall have provision to collect and drain the leakage from mechanical seal or packing, through a drip pan of metallurgy equivalent or superior to pump casing. Leakages from drip pan shall be piped to base plate with a flanged connection for onward disposal by purchaser. Where the design of bearing prohibits provision of drip pan, the material of bearing bracket shall be suitable for the corrosive service. 3.3.1.15 (New) The supports for the pump and motor shall be welded to structural members and not to flat plates. 3.3.1.16 (New) The base plate shall be provided with lifting lugs for at-least a four-point lift. Lifting the base plate complete with all equipment mounted shall not permanently distort or otherwise damage the base plate or machinery mounted on it. 3.3.2
Base Plate for Vertical Pumps:
3.3.2.3
(Modification) Alignment positioning screws shall be provided for 18.5 kW and above and as per manufacturer's standard practice for lower ratings.
34
PIPING & APPURTENANCES
3.4.1.1
(Substitution) Cooling water, lube oil and auxiliary process piping including all accessories such as gauges, valves, shall be furnished by the manufacturer fully assembled and installed on horizontal pumps and where practical on vertical pumps.
3.4.2.1
(Addition) Vendor shall provide gate valve at C.W. inlet line and Globe valve at the return line. Gate valve shall conform to API 602 with ASTM A105 body as CS + 13% Cr steel trim. Globe valve shall conform to BS5532 800# SW ASTM A105 Body and CS +13% Cr steel.
3.4.2.3
(Substitution) Carbon Steel piping conforming to A106 Gr.B Sch 80 shall be provided for cooling water unless otherwise specified. Socket welded/flanged connections shall be employed. Connections to pump pedestal, stuff box jacket or bearing housing jacket shall be screwed.
3.4.2.4
(Substitution) Sight flow indicator shall be provided in each outlet line. Sight flow indicator shall have ball or flag for easy verification of water flowing through pipes.
3.4.4.2
(Addition) Temperature indicator at the outlet of cooler shall be provided. For Figures D-3 Pressure switches and flow indicator shall be provided. Switches shall be suitable for the specified area classification, supply voltage and contact rating.
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(Modification) Unless otherwise specified material shall be stainless steel.
3.4.4.16 (New) Material for seal flushing liquid cooler shall be as per the following: Tube or Coil Type 316 stainless steel or Monel. Casing (or shell) Carbon Steel Cooling water shall be on the casing (shell) side. 3.4.4.17 (New) In case where operating condition warrants use of orifice and oil cooler in flushing plan for mechanical seal, oil cooler shall be installed upstream of orifice. SECTION 4 - INSPECTION AND TESTS 4.2
INSPECTION
4.2.4
(New) Inspection shall also include dimensional check of pump, driver and auxiliaries (if any) duly mounted on the base plate and check for direction of rotation of Pump Driver assembly in accordance with certified general assembly drawing.
4.3
TESTS
4.3.1.1
(Addition) Unless otherwise specified the test shall be witnessed by the Purchaser or by their authorized representative or by both together for operating as well as standby pumps.
4.3.1.3
(Substitution) Unless otherwise specified in the data sheet, the following tests shall be performed on each pump: 1. A witnessed hydrostatic test as per 4.3.2. or as specified in equipment data sheet. 2. A witnessed performance test as per 4.3.3. 3. A witnessed NPSH test as per 4.3.4 when difference between NPSHA and NPSHR is less or equal to 1 meter or when specified in the data sheets. 4. Shop Inspection per 4.2. 5. Dismantling inspection and reassembly, after the running test. 6. Dynamic balancing of rotating assembly including coupling half for between bearing pumps (Observed). 7. Dynamic balancing of impellers for Overhung pumps (Observed). 8. Other tests (if any) as specified else where
4.3.2.1
(Modification) Segmental Testing is not acceptable except for special design pumps as approved by purchaser.
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4.3.3.1
(Modification) Besides the four points mentioned in this clause, pump shall also be tested at rated flow and full valve open condition. The test duration shall be minimum four hours.
4.3.3.2
(Addition) Prior to start of test, manufacturer shall furnish the following: 1. Certificate of calibration of driver and measuring instruments, which should be recalibrated after a period of every one-year. Pressure gauges shall be calibrated prior to start of test and after completion of test. 2. Record of all running test and mechanical checks (including test curves and data) completed prior to the purchaser's inspection.
4.3.3.3
(Addition) Decision regarding trimming of impellers to meet the tolerances on differential head shall be taken only thereafter.
4.3.3.4
(Substitution) Shop driver shall be used for testing and the rating of the driver shall not exceed 150% of power that may be consumed while running at duty point with water; or power at full valve open condition, whichever is higher. The limitation of 150% is applicable only for medium voltage motors.
4.3.3.6
(Substitution) The tolerances for guaranteed characteristics stand modified as under: Rated head: Zero negative tolerance. Shutoff head: Zero negative tolerance. Positive tolerance permitted as long as Shutoff head does not exceed 120% of rated head. NPSH(R) Zero positive tolerance. Rated BKW: Zero positive tolerance (However pumps may be accepted upto 104% of Guaranteed BKW subject to Penalties as defined elsewhere)
4.3.3.8
(Addition) Vibration measurement shall be conducted for two points, minimum flow and rated flow and recorded as follows: Filtered Vibration at 1/2.1& Nx RPM
Description
Unfiltered Vibration
Velocity Displacement
Yes Yes Yes Yes - Where N = Blade, Vane, nozzle or diffuser Passing frequencies.
4.3.3.11 (New) During the performance test, rise in temperature of bearing oil shall be measured and results recorded on the test log. Values shall not exceed those given in 2.9.1.
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4.3.3.12 (New) During the performance test, the equipment shall be checked for its sound level at least at minimum and rated flow, value shall not exceed those given in 2.1.9 when measured without enclosure. 4.3.5
(New) After the performance test, 4 hours running test and NPSH TEST (if any) the pump shall be dismantled, to check for wear. Parts having close clearances and mechanical seal faces shall be checked for any abnormal rubbing and wear. Wear ring clearances shall be measured and recorded.
44
PREPARATION FOR SHIPMENT
4.4.1.6
(Modification) Flanged openings shall be provided with metal closure of 4.8 mm (3/16 inch) minimum thickness with rubber gaskets and atleast four full diameter bolts.
4.4.7
(New) Unless otherwise specified, the equipment shall be protected for a storage of 12 months at site, if any extra precaution is to be taken by the Purchaser for storage beyond 12 months the same shall be explicitly indicated in the operation and maintenance manuals.
4.4.8
(New) For multistage pumps, in case spare rotor is ordered, the spare rotor shall be crated in a metal container for transportation and storage. The crating method shall be suitable for at least 4 years storage in vertical position. The container shall be equipped for N2 blanketing. SECTION 6 - VENDOR'S DATA
6.1
PROPOSALS (Substituti&n) The vendor's proposals shall as a minimum include the following: a) All data sheets, drawings and documents listed under "PRINTS WITH QUOTE" in the enclosed Vendor Data Requirement Form. b) Vendor's confirmation/comments on post-order Vendor Data Requirements (Type of Documents, no. of prints and date needed) indicated in Vendor Data Requirement forms data sheets and specs. c) List of recommended commissioning spares included in the offer. d) List of mandatory spares (where specified by the purchaser) included in the offer. e) List of Vendor's standard Spare Parts for Two Years Normal Operation This list shall be made separately for each items including auxiliaries and drivers in the form of a table & shall show : i) Part name, description and number. ii) Quantity installed in one unit. iii) Quantity recommended per unit for 2 years normal operation.
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iv) Quantity recommended for number of units of an item as specified in the inquiry. v) Quantity recommended as insurance for the number of units of an item specified in the inquiry. f) An itemised list of special tools included in the offer. g) Any start-up, shutdown or operating restrictions required to protect the integrity of the equipment. h) Any limitations of vendor's test-facility to carryout the specified tests. i) A specific statement that the scope of supply, the offered equipment/systems and all its components are in strict accordance with the data sheets, job specifications, this specifications and all other attachments, except for specific deviations as listed in the proposal. 6.2
CONTRACT DATA (Substitution)
6.2.1
General
6.2.1.1
Drawings and data as required after purchase order has been specified in Vendor Data Requirement. Vendor to note that the drawing/document descriptions/titles as given in the Vendor Data Requirement are generic in nature. It is possible that against one drawing/document specified there are several drawings to be furnished by the vendor or vice versa. Vendor shall complete & forward a document "Vendor Data Index & Schedule" to the purchaser (Destination & contact person as per order). This document shall list out in consolidated form all drawings and documents required by purchaser (As specified in Data Sheets, Specifications and Vendor Data Requirement forms enclosed with the order). Against each drawing/document vendor shall indicate the vendor's drawing numbers, titles. Rev. No., category (whether for information or approval) and schedule of submission. This shall be the first document to be submitted by vendor within two weeks of order.
6.2.1.2
All transmittal letters (covers), drawings and data shall have a title block (in addition to vendor's standard title block) which shall as a minimum contain the following contract information: i) Purchaser's and Consultant's Corporate Name ii) Project Name. iii) Equipment Name and Item No. iv) Purchase Order No. v) Purchase Requisition No. Title Block on drawings shall be placed on the lower right hand corner.
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6.2.1.3
All vendor data/drawings/documents shall be in English Language and in Metric Systems.
6.2.1.4
Data specified in the VDR is the minimum requirements of Purchaser. Any additional document/data required or requested by Purchaser for engineering or construction shall also be made available by the vendor.
6.2.1.5
Whether or not specified the vendor shall furnish the following, before shipment: As built running clearances and when applicable; thrust bearing, radial bearing and seal running clearances. A supplementary list of spare parts other than those included in his original proposal. The supplementary list shall include recommended spare parts, crosssectional or assembly type drawings, parts numbers, materials, prices and delivery period. The vendor shall forward this supplementary list to the purchaser promptly after receipt of the reviewed drawings and in time to permit order and delivery of parts before field start-up. A parts list for all equipment supplied. The list shall include pattern, stock, or production drawing numbers and materials of construction. The list shall completely identify each part so that the purchaser may determine the interchangeability of the parts with other equipment furnished by the same manufacturer. Standard purchased items shall be identified by the original manufacturer's name and part number. At least 8 weeks before shipment, the vendor shall submit his preservation, packaging and shipping procedures to the purchaser's for his review.
6.2.3
Co-ordination Meeting When specified, a co-ordination meeting shall berheld at Purchaser's office, preferably within 4 weeks of order. s An agenda shall be prepared for this meeting and would include the following points related to technical aspects. a. Any clarifications required by the vendor on purchaser's order. b. Vendor Data Index & Schedule. c. Vendor Data Review/approval modalities. d. Sub-vendor lists proposed by vendor. e. Utility requirements. f. Preliminary General Arrangement & layout drawings & purchaser's interface drawings.
6.2.4
Drawings
6.2.4.1
The number of prints and/or reproducible required and the times within which these are to be submitted by vendor are specified in Purchaser's inquiry/order.
6.2.4.2
The purchaser's review of the vendor's drawings shall not constitute permission to deviate from any requirements in the purchase order/specifications unless specifically agreed upon in writing. After the drawings have been reviewed, the vendor shall furnish certified copies in the quantity specified. All drawings must be
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clearly legible and shall be folded to 216 mm x 279 mm size. All transparencies shall be rolled. 6.2.4.3
ii)
Drawings/documents with following titles shall contain as a minimum the following information: a) General Arrangement Drawing A general arrangement drawing shall indicate: i) Outline dimensions (minimum three views) (All principal dimensions). Allowable forces and moments on suction and discharge nozzles.
iii)
Location (in all three planes), size, type, rating and identification of all purchaser's interface connections including those of vents, drains lubricating oil, sealing fluid, cooling water, steam & Electrical/Instrumentation. iv) Direction of rotation viewing from the driving end. v) Weight of each assembly/component. vi) The weight & location of center of gravity of the heaviest assembly/components that must be handled for erection. vii) Identification and weight, dimensions of the heaviest assembly / subassembly / component required to be handled for maintenance. viii) Maintenance clearances and dismantling clearances. ix) Speeds of Driven Equipment and Driver with Driver rating. Location of driver terminal box (in case of Electric Motor Driver) x) Layout of auxiliary equipment and operating platform as applicable. xi) Make, Type and Size of couplings and the location of guards and their coverage. xii) A list of reference drawings if any. xiii) A list of any special weather-protection and climatic features. xiv) Line diagram of sealing piping indicating direction of flow of fluid by arrow and inlet and outlet. b) Foundation Drawings A foundation drawing shall indicate complete information required for foundation design by purchase including the following: i) Foundation bolt sizes, pipe sleeve details, pocket sizes and locations. ii) Grouting thickness and other necessary technical details. iii) Static weight of each skid/independently grouted item and location of center of gravity of each of such skid/items in all three planes. iv) Weight distribution for each bolt/subsole plate location and total static weight. v) Dynamic loading caused due to various items grouted independently. vi) The direction and magnitude of unbalance forces and moments generated by each such item at the worst operating condition and short circuit moments of motor drivers/generators. vii) GD2 value of each item resolved to driver speed. viii) Maximum permissible amplitude of vibration on the foundation at base level. ix) Total mass of rotating parts. x) Suggested dynamic factor and ratio of foundation weight to weight of skid/equipment as per vendor experience.
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c) Layout Drawing (For multi-skid packages) This drawing shall include atleast the following: i) Layout of all skid/equipment and their auxiliaries, vessels, control panels, exchangers etc. Vendor shall furnish an optimized layout (considering the space allocated, site wind conditions, area classification, the type of equipment located in the vicinity etc.) indicating elevation and dimension of skids/equipment. ii) Minimum spacing required between the various skids/equipment and between the skids and the walls/columns/roof for an easy accessibility and maintenance. iii)
Layout for water piping, trenches for water piping, cable tray/trenches layout. iv) Piping arrangement and piping support arrangement/location for piping in vendor's scope. v) Layout for auxiliary equipment and operating platform details. vi) Specification for crane/mono rail (including suggested mono rail layout) recommended for maintenance and height of the lifting hook from the centerline of equipment. d) Field Alignment Diagram The diagram shall indicate the relative displacement to be kept between the centrelines of various equipments at the time of installation, so that under normal running conditions the equipments get fully aligned. This relative displacement should be decided on the basis of centerline temperature rise data of driver, gear box/transmission system, driven equipment. e) Heat Exchanger Drawings Heat exchanger drawing and data shall include heat and mass balance data, details of provisions for separating and withdrawing the condensate, construction details, cross sections & general arrangement drawings of heat exchangers, vendors recommendations regarding provision for support and piping expansion. 6.2.4.4
P&I Diagrams (with Bill of Materials) Vendor shall supply P&I Diagrams along with Bill of Materials of each system in the vendor's scope of supply or specified in the order. P&I Diagram shali indicate the system details, location of various auxiliaries, instruments, controls and safety devices as required. Line sizes, piping class, valve sizes and class shall be clearly marked on the P&ID. Vendor's scope and purchaser's scope shall be clearly demarcated. Each item shall be identified by an item No./item tag no., which shall correspond to the item no. shown on the bill of materials. The bill of materials shall include items number, normal value, set value, range, quantity per unit, make and other specifications as applicable. Legends adopted shall be indicated either at the bottom of drawing or on a separate drawing. The legends shall be as per ISA.
6.2.4.5
Cross-sectional Drawfng(with Bill of Materials) The vendor shall supply cross-sectional or assembly type drawings for all equipment furnished showing all parts, design assembly and running clearances, and balancing data required for erection and maintenance. Each part shall be numbered which shall correspond to the part number on the bill of materials. The bill of materials shall include the part no., name of component, materials quantity installed per unit & sizes
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where applicable (say for bolts, nuts, rings, gaskets etc.). All bought out items shall also be indicated with make and brief specifications. A separate cross-sectional drawing showing installation and setting dimensions for the seals shall be furnished. 6.2.5
Performance Characteristic Curves
6.2.5.1
The vendor shall provide complete performance curves to encompass the map of operations, with any limitations indicated thereon.
6.2.5.2
All curves submitted prior to final performance testing shall be marked "PREDICTED". Any set of curves resulting from a test shall be marked "TESTED".
6.2.5.3
Certified test curves and data shall be submitted within 15 days after testing and shall include head, power recalculated to the proper specific gravity and efficiency plotted against capacity. If applicable, viscosity corrections shall be indicated. If NPSHR test is specified, the water NPSHR curve (drawn upto minimum continuous flow) shall also be included. The curve sheet shall include the maximum and minimum diameters of the impeller design supplied, the eye area of the first stage impeller, the identification number of the impeller or impellers and the pump serial number.
6.2.6
Data Sheet
6.2.6.1 The Vendor shall provide completely filled in data sheets, first for "As Purchased" and then for "As Built". This shall be done by the vendor correcting and filling out the data sheets and submitting copies to the purchaser. 6.2.7
Technical Data Manual/Mechanical Catalogues
6.2.7.1 Technical Data Manual/Mechanical Catalogue is a compilation of "as built" drawings and data, manufacturing and test records, installation, operating and maintenance instructions. 6.2.7.2 Not later than two weeks after successful completion of all specified tests, the vendor shall furnish the required number of Technical Data Manual/Mechanical Catalogues for the equipment, any auxiliaries and instruments that the vendor is providing. The Technical Data Manual/Mechanical Catalogue shall include the following documents as a minimum: i) All drawings and data as listed in the vendor data index & schedule. (For drawings, where purchaser's approval is required, the final certified drawings shall be attached.) Sections shall be organized in a manner that data & drawings related to one subject is grouped together such as Mechanical, Electrical, Instrumentation etc. ii) All manufacturing, inspection and test data and records. iii) Installation and Instruction Manual The vendor shall provide sufficient written instructions, including a crossreference list of all drawings, to enable the purchaser to correctly install the equipment and prepare the equipment for start-up. It shall include any special information required for proper installation that is not on the drawings, special alignment or grouting procedures, utility specifications (including quantity) and all installation data. It shall also contain the following information:
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Instructions for erecting, piping, aligning (including the expected thermally induced shaft centerline shift between normal site ambient temperature position and that at normal equipment operating temperature). (b) A description of rigging procedures, including the lifting of the assembled equipment, and methods of disassembly, repair, adjustment, inspection and reassembly of the equipment and auxiliaries. (a)
(c) Pre-commissioning/commiss ioning/functional test procedures and acceptance criterion. iv) Operation and Maintenance Manual This manual shall provide sufficient written instructions and data to enable purchaser to correctly operate and maintain the equipment ordered. It shall include a section to cover special instructions for operation at extreme environmental and/or extreme operating conditions. The following shall be included in this manual: (a) Instructions covering start-up, normal shutdown, emergency shutdown, operating limits and routine operational procedures. (b) A description of equipment construction features and the functioning of component parts or systems (such as control, lubrication, sealing systems etc.). (c) Outline and sectional drawings, schematics and illustrative sketches in sufficient details to identify all parts and clearly show the operation of all equipment and components and the methods of inspection and repair. Standardised sectional drawings are acceptable only if they represent the actual construction of the equipment. (d) The following maintenance Information: i. Maximum and) minimum bearing, labyrinth and seal clearances including any other clearance between moving and stationary parts of the equipment affecting proper running and maintenance of the equipment. ii. Instructions for measuring and adjusting cold clearances, shaft runout, concentricity etc. iii. Rotor float allowance. iv. Interference fits on parts that are required to be removed or replaced for maintenance of normally consumable spares. v. Balancing data with permissible unbalance. vi. Lubricating schedules indicating recommended grades of oil, their properties, replacement period etc. vii. Normal maintenance procedure. viii. Preventive maintenance schedules and criterion for replacement of parts. ix. Trouble - shooting procedures. (e) The following reassembly information: 1. Bolting sequence and torque values for all bolts affecting equipment performance/integrity/safety. 2. Reassembly sequences together with required inspection checks. 3. Adjustment procedures to achieve required positions, clearances, float and so forth. 4. Detailed procedures for pre-operational checks, including settings and adjustments. 5. Seals and coupling installation procedures. 6. Parts list indicating cross-sectional drawings of various assemblies and sub-assemblies, part numbers, materials of construction (ASTM) etc. to facilitate identification of parts and for procurement of spares.
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1. 2.
3.
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Owing information shall also be included in the Technical Data Manual/Mechanical Catalogue: Storage instructions for storing and preserving the equipment (including driver and all the auxiliary units) at the plant site before installation of the same. Instructions for preserving the equipment after it has been installed. This is particularly required in cases where a long time gap is expected between equipment installation and commissioning. Field performance test procedures and acceptance criterion. 6.2.7.3 Technical Data Manual/Mechanical Catalogue shall be in Hard board folder(s) of size 265 mm x 315 mm (10.5" x 12.5") and shall not be more than 90 mm thickness; it may be of several volumes and each volume shall have a volume number, index of volumes & index of contents of that particular volume. Title sheet (Top sheet) of each volume of Technical Data Manual/Mechanical Catalogue shall contain the contract information as defined under 5.2.1.2 besides the volume number.
6.2.7.4
In case order contains more than one item, separate dedicated technical data manual / mechanical catalogues shall be submitted for each item.
6.2.7.5
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SPECIFICATION FOR HOSES, EXPANSION JOINTS & VALVES
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Specification of Flexible Corrugated Hose Type: Stainless steel corrugated Hose Conforming to BS: 6501, Part-I-2004 and ISO 10380 Hose Material: AISI: 304 Braiding: two layers, Braiding Material: AISI-304 Ends: Floating Flange, Material: AISI-304 Flexibility: Type C for maximum flexibility Suitable for Temp range upto + 800 degree Celsius Quality Assurance: All hoses shall be subjected to i) ii) iii) iv)
Life Cycle Test or Fatigue Test Burst Pressure test Bend Radius test Flame test
Specification of Metallic compensators/ Expansion Joints for Pumps handling hot fluid All the pumps handling either Thermic Fluid or Coal Tart Pitch are to be provided with stainless metallic compensator/ expansion joints on both suction and delivery side to suit pressure rating of minimum 150 PSI and temperature up to 800 degree Celsius. Test pressure for the compensators shall be at least 225 PSI. Ends shall be flanged and as per ANSI B16.5. Bellows shall be hyfroformed for minimal residual stress and minimal thinning at the convolution and crown. Material for bellows shall be AISI 304.
Specification of Metallic Pipe compensators/ Expansion Joints for Piping Vendor shall provide adequate nos. of metallic compensator in suitable distance and at bends to handle thermal stress, vibration and axial movement. The compensators shall be made of multiply stainless steel bellows (AISI-321) and housed in carbon steel casing. Design Data: Temp. up to 450 degree Celsius, Press. 175 PSI, Test Press. 250 PSI
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Specification of
Gate Valves:
Standard: API 602 Rating: 800 Piping Class- A1A, A3A, JI1 Ends: SW 3000 to ANSI B 16.11 Body: Forged – ASTM-105 Bonnet: - Bolted – ASTM 105 Stem – Rising – 13 % CR steel Wedge Disc – Solid – 13 % CR steel Body Seat ring – renewable - 13 % CR steel Stem Packing – Renewable – PTFE Hand wheel – Non- rising – Cast Steel Bonnet Bolts – ASTM A 193 Gr. B7 Bonnet Nuts – ASTM –194 – GR 2H Bonnet Gasket - SP WND SS304 + CA Filler Service Condition: Max. 425 degree Celsius Hydrostatic Test pressure – 3000 PSI G Test pressure with AIR- 80 PSI G Testing as per API 598
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Standard: API 600 Rating: 150 Piping Class- A1A, A3A Ends: Flange to B 16.5 Body: Cast - ASTM A 216 GR. WCB Bonnet: - Bolted – ASTM A 216 GR. WCB Stem – Rising – 13 % CR steel Wedge Disc – Solid – 13 % CR steel Body Seat ring – renewable - 13 % CR steel Stem Packing – Renewable – PTFE Hand wheel – Non- rising – Cast Steel Bonnet Bolts – ASTM A 193 Gr. B7 Bonnet Nuts – ASTM –194 – GR 2H Bonnet Gasket - SP WND SS304 + CA Filler Service Condition: Max. 425 degree Celsius Hydrostatic Test pressure – 3000 PSI G Test pressure with AIR- 80 PSI G Testing as per API 598
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Specification of GLOBE Valves:
Standard: BS- 5352 Rating: 800 Piping Class- A1A, A3A, JI1 Ends: SW 3000 to ANSI B 16.11 Body: Forged – ASTM-105 Bonnet: - Bolted – ASTM 105 Stem – Rising – 13 % CR steel Wedge Disc – Solid – 13 % CR steel Body Seat ring – renewable - 13 % CR steel Stem Packing – Renewable – PTFE Hand wheel – Non- rising – Cast Steel Bonnet Bolts – ASTM A 193 Gr. B7 Bonnet Nuts – ASTM –194 – GR 2H Bonnet Gasket - SP WND SS304 + CA Filler Service Condition: Max. 425 degree Celsius Hydrostatic Test pressure – 3000 PSI G Test pressure with AIR- 80 PSI G Testing as per BS 6755 (Part-1)
Notes: i)
Unless called out specifically valves shall conform to following, - Gate valve ½ inch to 1-1/2 inch, Rating : 800 , API-602, testing: API 598 - Globe/ Check valve ½ inch to 1-1/2 inch, Rating:800, BS-5352, testing: BS 6755- Part-1 - Gate valve 2-24 inch 300 class conform to API-600 & API-598 - Globe Valve 2-8 inch, 300 class shall be as per BS-1873 and testing as per BS-6755, Part-1
ii)
Unless and otherwise stated, geared operators for valves shall be furnished for the following sizes, - Gate & Globe Valves, ANSI class 125 – 18 inch and larger, - Gate & Globe Valves class 150 14 inch and larger
iii)
Radiography wherever required shall be in accordance with ANSI B16.34 procedure and acceptance standard as per annexure- “B” of ANSI B16.34
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STEEL BELLOWS SEALED GLOBE VALVES:
Pressure: 16 – 100 Bar Temperature (oC) : -29 to 427 Class: ANSI 300 Feature: Zero Emission, Graphite Stem Packing, with position indication, with heating jacket, Admissible Pressure: as per DIN 3356 Flanged as per ANSI B 16.5 Body: Carbon Steel Cast (A 216 WCB) Extended Bonnet: ASTM A 105 Seat Ring: SAE AISI 316L Facing: Flat Stainless steel Stem: SAE AISI 316L Guide Bushing AISI 430 F Gasket Packing: Graphite + SAE AISI 316L Bellows: SAE AISI 316 Ti Stud & Nut: ASTM A 193 B7 + A 194 2H Seat: Welded: X2 Cr Ni Mo 17-12-2 Disc: X2 Cr Ni Mo 17-12-2 Hand wheel: Steel Test as per ISO – 5208/ API 598/ BS: 6755 Part-1 Radiography as per ANSI B16.34 Manufacturing Standard: BS: 1873 & 5352
PNEUMATIC ACTUATOR:
SMELTER DIVISION
Type: Piston type double acting Safety Position: Air fail remain in position Positioner: electro-pneumatic Air Filter: Modular, Make: Joucomatic/ Legris/ Parker Air Pressure: 05 BAR
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FLANGED JACKETED PLUG VALVE:
Operation: Pneumatic Actuated (Double Acting) Air pressure: 05 BAR Class: ANSI 300 Temperature (oC) : -29 to 427 Body: GS-C25 (216 WCB) Sleeve: Graphite Diaphragm: PTFE Cover: GS-C25 (216 WC) Packing: Graphite Adjusting screw: DIN 976 Nut: DIN 936 & DIN 934 Plug: 316/ A 351 CF & M Jacket: CS GS-C25 (216 GCB) Mechanical test as per ASTM A 370/92 Manufacturing As per ASTM A 216/93 / BS: 6755 Flanged as per ANSI B 16.5 Test as per ISO – 5208/ API 598/ BS: 6755 Part-1/DIN 3230 Radiography as per ANSI B16.34 Manufacturing Standard: BS: 1873 & 5352
PNEUMATIC ACTUATOR:
SMELTER DIVISION
Type: Piston type double acting Safety Position: Air fail remain in position Positioner: electro-pneumatic Air Filter: Modular, Make: Joucomatic/ Legris/ Parker Air Pressure: 05 Kg/ CM2 Max.
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SPECIFICATION FOR VESSELS & STORAGE TANKS FOR GREEN ANODE PASTE PLANT
SMELTER DIVISION
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TECHNICAL SPECIFICATION FOR BINS / SILOS, VESSELS & STORAGE TANKS
GENERAL Basic process data sheets/description, job specifications, Standard specifications & standards are attached in the requisition. Vendor shall strictly follow the same. In case of conflict, the most stringent requirements shall govern, however it shall be resolved considering the most stringent in following order : i)
Requisition and agreed variations to it
ii)
Drawings / process data sheets
iii)
Job specifications / standards
iv)
Standard specifications / standards
v)
Codes
Further the interpretation most stringent or most favourable to Owner shall govern and shall be binding on the contractor /vendor. In case of contradiction contractor shall bring the same to the notice of NALCO in writing and proceed for execution only after due approval. National laws and statutory provisions together with any local laws for the state shall be complied with. 1.0
VENDOR'S SCOPE OF WORK Design for all equipments, detailed engineering, materials, fabrication,/ PWHT/Stress relieving, inspection, testing, fitting of other attachments, insulation, fire proofing, internal packings, cleaning, surface preparation and painting, supply & erection of equipment as per process data sheets/description, requisition, job specifications, standard specifications & standards. The standard specifications & standards are intended to supplement the minimum requirement of the applicable codes. In addition to this vendor has to install equipment, internals etc., wherever required. The scope of work and supply of equipment shall include but not be limited to all bins, silos, vessels and storage tanks shown in the
SMELTER DIVISION
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PFDs/P&IDs, basic design engineering package, requisition etc. as defined in the requisition. Vendor's scope of work and supply shall include all equipments to complete the works within the battery limits in all respects.
1.1
For VESSELS Complete Mechanical design (i.e. design of shell, heads, nozzles, flanged openings, supports, anchor bolts, wt. calculation, wind and seismic analysis. RF pad calculation, design of partition plates/baffles/internals and local load analysis as per WRC 107/297 or BS5500 etc.) as per relevant code as defined in specification and additional requirements in process data sheets/description/special instructions and requisition attached with this package. Type of supports shall be decided by contractor based on standards.
1.2
FOR TANKS Complete design (i.e. design of shell, Bottom, Roof, Roof structure, nozzles, flanged openings, R.F. Pads, Wind Girders, Compression area checking, Counter balancing weight, anchorage requirement, Cooling and Foam system/Fire Fighting System etc.) as per the requisition and NALCO Specifications/Standards and Codes.
1.3
Orientation of all nozzles for these equipment shall be fixed by vendor.
1.4
All internals and their assembly coming inside the equipment shall be in vendor's scope.
1.5
Installation of all mounting and accessories etc. on equipments.
1.6
Fabrication and supply of all process equipment with all accessories such as stairways/ladders, roof structure and wind girders for tanks, operating/ maintenance platforms, stiffener rings, nozzles and other accessories etc. as per the scheme approved by NALCO.
1.7
Getting statutory approvals such as IBR approvals etc. wherever required from national/state agencies.
1.8
Carrying out Heat Treatment/PWHT wherever required.
1.9
Carrying out all non-destructive testing like dye penetration, ultrasound testing and radiography and all other tests as mentioned in the requisition/specifications & applicable codes.
1.10
Erection of all equipments in position/foundations as per the requirement of requisition. Bolting, grouting on supports/foundations as required.
SMELTER DIVISION
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1.12
Carrying out hydrotesting/pneumatic/vaccum tests as specified in specifications/ drawings/codes and as per instruction of Engineer-inCharge.
1.13
Carrying out insulation, fireproofing, surface preparation, pre-erection primer application, primer and painting as per NALCO specification.
1.14
Submission of documents as per vendor data requirements enclosed with the package.
1.15
Arranging for instruments, tools, tackles, support stiffeners, temporary attachments/platforms etc. for fabrication, welding, inspection, testing and completion of the entire work.
1.16
Submission of monthly progress reports, bar charts, planning and scheduling of all activities for completion of the entire job.
1.17
Cleaning of work area as per instructions of Engineer-in-Charge after completion of the job.
1.18
Providing sight/light glasses for inspection/operating requirements as per approved scheme.
1.19
Pickling and passivation of stainless steel surfaces.
1.20
Completion of all works as required vide requisition/ specifications/ standards/codes and instructions/satisfaction of the Engineer-inCharge.
2.0
VENDOR'S SCOPE OF SUPPLY
2.1
Procurement and supply in sequence and at appropriate time of all materials (metallic & non metallic), consumables and non-consumable for all equipments required to complete the job as per requisition/approved scheme by NALCO.
2.2
Supply of all internals/attachments, sight/light glasses etc. Supply of insulating material, primer & paints, fire proofing materials wherever required. Supply of materials/equipment required for blast cleaning/surface preparation of equipments.
2.3 2.4
SMELTER DIVISION
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2.5
Supply of all tools & tackles, equipment, consumable/non consumable materials required for inspection and testing (i.e. NDT, hydrotesting etc.).
2.6
Supply of all other materials whether specifically mentioned or not but required for completion of the job in all respect as per requisition.
2.7 All approach ladders, platforms (independent & interconnecting) for different accessories, instruments, operating valves etc. shall be included in the contractor's scope and all layout and design shall be as per requirements of requisition/approved drawings. 3.0
SPECIAL INSTRUCTIONS
3.1
All vessels and tanks shall be designed by vendor as per ASME Sec. VIII Div.l and as per API 650/API 620 respectively. In addition vessels which are under IBR shall be designed meeting IBR requirement. All design calculations shall be made considering all loads for erection, operating and hydrotest condition.
3.2
All vertical vessels shall be designed so as to permit site testing of the equipment in vertical condition with test pressure as per code at the top with the vessel completely filled with water plus 33% wind load. The design shall be based on fully corroded condition. All equipments shall be hydrotested in accordance with scheme approved by Engineerin-Charge.
3.3 Wind and Seismic design data shall be as per the specification enclosed.. 3.4
For hydrotest, gasket specification shall be same as service gaskets.
3.5
Burried equipment shall be designed for external pressure due to earth load and also anchoring shall be provided meeting full uplift due to water table present in empty condition (corroded condition) and for anchor bolts corrosion allowance of 6 mm shall be considered. Nozzle projection shall be brought out of soil level and shall project minimum 400 mm from Finished Grade Level.
3.6
All internals, which are fixed, shall be designed for full load condition and also twice the corrosion allowance shall be considered. Internals, which are of bolted construction, shall be designed with single corrosion allowance.
SMELTER DIVISION
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3.7
For jacketed vessel/tanks inner shell shall be designed minimum for external pressure equal to internal pressure of the jacket.
3.8
All vertical vessel supports design shall meet the minimum requirements as given in this document. . Skirt supports shall be provided for all vertical vessels. Only small vertical vessels may be supported on legs or brackets.
3.9
All dished ends shall be deep torispherical as per IS-4049 or 2:1 semi ellipsoidal or as per Process data sheet/description. Dished ends upto 2.5 m dia shall be in single piece.
3.10
Radiography shall be as per Specification/Code however spot radiography is the minimum requirement for all pressure vessels including vessels (tanks/ bins/ silos/vessels) full of liquid and atmospheric vessels.
3.11
All nozzles and reinforcing requirements shall be min. as per code. However reinforcement pad width, nozzle projection shall be as per standard as a minimum.
3.12
The internals shall be of same material as the shell and head unless otherwise stated in process data sheets/description.
3.13
All materials used for construction of Bins/Silos, vessels and tanks shall be as per Process data sheets/description, requisition, job specifications and Standard specifications enclosed with the requisition.
3.14.1
However if carbon steel is used then : (a)
IS-2062 Gr. A (Silicon killed steel) or better shall be used for Bins/Silos, vessels and tanks having design pressure equal to atmospheric pressure and design temp, up to 250°C.
(b)
SA-516 Gr. 60/70 or better shall be used for equipment having design pressure more than atmospheric pressure and/or design temp, above 250°C.
(c)
For dished heads where forming is required shall be of boiler quality steel only.
(d)
All boiler quality C.S. Plates shall confirm to laid down specification.
(e)
All strl. quality C.S. Plates shall confirm to specification.
SMELTER DIVISION
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(f)
Forgings shall be as per SA-105 and pipes shall be as per SA-106 Gr. B upto ' 250 mm NB. Above 250 mm NB plates can be used for nozzle necks with 100% radiography.
3.14.2
Stainless steel material shall confirm to specification .
3.14.3
Corrosion allowance for CS equipment shall be assumed as 3.0 mm minimum while the same for SS equipment shall be assumed as nil, if it is not specified on process data sheet/description.
3.14.4
Minimum thickness of carbon steel plates used for shell/head shall be 6.0mm and minimum thickness of stainless steel plates used shall be 3.0mm.
3.15 For pressure vessels, standard specification in the document shall be followed. 3.16 For Storage tanks, standard specification in the document shall be followed. 3.17 All flanges shall be as per ANSI B16.5 upto 600NB and as per ASME B16.47 series B above 600NB. Gaskets, bolting and flange facing shall be as per piping material specification. 3.18 Minimum course width shall be 1 metre. Maximum no. of longitudinal seams shall be as follows: Equipment upto 2 metre diameter Equipment from 2 metre upto 4 metre dia. Equipment from 4 metre upto 6 metre dia. Equipment from 6 metre upto 12 metre dia.
: : : :
1 Seam 2 Seam 3 Seam 4 Seam
3.19
Equipments shall be provided with vent nozzles, inspection nozzles as per spec./code.
3.20
2 nos. - Lifting lugs for Bins/Silos and vertical vessels (having diameter > 1000 mm or weighing > 1000 Kgs.) shall be provided as per Standard. Shell shall be suitably stiffened at lifting lug locations to take care off loads during lifting.
3.21
Min. Anchor bolt size shall be M24 (anchor bolt size specified is exclusive of corrosion allowance).
3.22
Nozzle with companion flanges/manholes to be provided with gasket and bolting. All manholes shall be provided with davit. Manhole covers to be
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provided with stainless steel jack bolts for easy detachment during maintenance.
3.23
Equipment foundation shall be designed for hydrotest condition as well as operating condition with seismic / wind loads whichever is governing with equipment in new condition.
3.24
Ensure temperature of the concrete foundations of equipments is not higher than 80°C during operating conditions. Otherwise suitable load bearing refractory materials to be used to ensure the above.
3.25
Pickling & Passivation for all SS surfaces (both inside & outside) shall be carried out.
3.26
For all SS equipment the plates, welds & HAZ shall be IGC tested as per ASTM A-262 Practice E. IGC requirement indicated in standard specification enclosed.
3.27 Leg and skirt supports for all vertical vessels shall be provided with fireproofing. 3.28
For blast cleaning of steel surface Electro Corund (Aluminium Oxide particle size 0.8mm-1.2mm) or steel/crushed chilled iron grit or malleable iron and steel shots shall be used. Sand or other potentially Silicon containing materials shall not be used as abrasives for blast cleaning because of safety regulations.
3.29
Painting of Bins/Silos, vessels and storage tanks shall be done as per specification.
3.30
Thermal loads and expansion/contraction of components/equipments shall be considered during design and detailed engg. for equipments operating at temperatures higher than 80°C.
3.31
Note ail mandatory spares, spares required for commissioning to be included in the scope of supply of the vendor.
3.32
Detailed quality assurance plans shall be prepared by the contractor and got approved from the Inspection Agency on award of the job.
3.33 (a) i) indigenous
SMELTER DIVISION
Equipment shall be procured from the NALCO approved vendors for
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supplies. A list of approved vendors is enclosed. In case any vendor other than those listed in the enclosed vendor list is to be considered, the approved status of proposed vendors shall be checked from NALCO prior to placement of order. ii) For overseas suppliers the performance track record (PTR) of the supplier to be indicated for similar supplies in past. Details of PTR to be furnished to NALCO for review/approval before detailed procurement activities are taken up by the contractor. (b)
Contractor shall subcontract work only to NALCO approved subcontractors.
(c)
Equipment shall be fabricated in shops approved by NALCO.
3.34
All vessels shall be transported to site in single piece. If it is not possible and site fabrication is involved, a detail procedure for site fabrication, assembly, testing etc. including welding procedure and qualifications, shall be submitted to NALCO for approval before start of site work.
3.35
Contractor shall generate all data required for complete procurement, fabrication, inspection, testing and supply of equipments based on guidelines furnished in the requisition.
3.36
Contractor shall be responsibile for generating adequate and true design data for equipments whose design data is not furnished with the requisition. The design data for all equipments shall be got reviewed by NALCO before proceeding with detailed design.
3.37
Inspection Agency shall be NALCO/its authorized agency for indigenous supplies. For overseas supplies Inspection Agency shall be Lloyds/TUV/Bureau Veritas or any other reputed Inspection Agency approved by NALCO.
40
MANDATORY SPARES
4.1.1
Supply of all spares for each handhole/manhole.
4.1.2
SMELTER DIVISION
a)
10% fasteners (minimum 2 nos.),
b)
200% gaskets (minimum 2 nos.)
Sight/light glass assembly (4 sets for each installed assembly)
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4.2
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These spares are excluding fasteners/gaskets required for hydrostatic
testing and despatch. 50
DRAWINGS/ DOCUMENTS REQUIRED FROM CONTRACTOR AFTER AWARD OF CONTRACT:-
51
NALCO SHALL DO SAMPLE REVIEW OF DRAWINGS / DOCUMENTS. Vendor to submit a detailed drawing schedule for all items giving serial number, description of drawing, drawing number and revision number. Calculations/drawings/documents for items needing NALCO review shall be marked on the contractor's drawings schedule by NALCO after award of contract. Other drawings/calculations/documents shall be for records.
5.2
Design calculation shall be submitted in detail i.e. giving complete break-up of calculation / indicating formula & reference etc. If contractor uses computer programs / softwares then it shall be validated by any reputed third party and validation report / certificate & name of validation agency shall be furnished along with design calculations.
5.3
All design calculation and fabrication drawings to NALCO for review, based on and bearing reference number and revision of the corresponding vendor’ drawings/sheets/description. In addition it shall indicate item number, company's name, job number, project name, client' name, fabricator's name, drawings number, revision number etc. all in the lower right hand corner. All revisions shall be clearly marked by encircling with revision marks.
5.4
Documents/Drawings as required in vendor data requirements.
5.5
All drawings/documents shall be thoroughly checked and duly signed by contractor. Unchecked drawings and drawings without revisions clearly marked shall be returned without review. Successive review of the same fabricator's drawing shall apply only to Nalco’s latest sheet/description/comments on the previous revision. Drawings and documents returned to fabricator for revision shall be resubmitted.
5.6
Nalco’s review of contractor's drawings and documents must not be considered as a check and shall not relieve the fabricator of his responsibilities to supply equipment as per requisition. Contractor shall
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remain responsible for conflicts between his drawings/documents and NALCO documents. 5.7
Design and drawings prepared by the sub-contractors or vendors of main contractor shall be thoroughly checked, duly signed and stamped by die main contractor before submitting the same for review of NALCO.
5.8
Approval for any revision and or modifications to die reviewed documents shall be taken from NALCO before implementation
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VENDOR DATA REQUIREMENT FOR BINS/SILOS, VESSELS & TANKS DESCRIPTION
NO. OF PRINTS WITH
DESIGN CALCULATIONS lh
DOCUMENTS REQUIRED AFTER PURCHASE REQUISITION FINAL COPY IN TRANS -PARENCY NO. OF COPIES
DURATION IN WEEKS
2
PRINTED MATTER NO. OF COPIES 6
REMARKS
3 TO 5
GENERAL ARRANGEMENT DRAWING INDICATING DESIGN DATA FABRICATED EQUIPMENT WEIGHT. GENERAL NOTES, NOZZLE SCHEDULE. DETAIL OF SHELL, HEADS. SKIRT SUPPORTING ARRANGEMENT. MAIN WELD
■
SEAMS.NOZZLE ORIENTATION PLAN. CUTTING LAYOUT ETC.
2
6
3 TO 5
2
DETAIL OF NOZZLES. MANHOLES. ACCESSORIES ETC.
2
6
3 TO 5
3
DETAIL OF INTERNALS
2
6
3 TO 5
4
DETAIL OF EXTERNAL CUPS SUCH AS LADDER. PLATFORM, PIPE SUPPORT.
2
6
3 TO 5
2
6
4-6
2
6
IN EACH DRG.
INSULATION. FIRE PROOFING. DAVITS. LIFTING LUGS ETC. 5
SHELL DEVELOPMENT DRAWINGS INCORPORATING ALL ATTACHMENTS AND WELD SEAMS
6
BILL OF MATERIAL FOR EACH ITEM SHOWING PART SIZE. 0UANT1TY. MATERIAL SPECIFICATION. SCOPE OF SUPPLY AND WEIGHT ETC.
+
7
FABRICATION PROCEDURE.MATERIAL TEST CERTIFICATES (FABRICATOR'S SUPPLY!
6
AS PER INSPECTION PROCEDURE
+
8
WELDING PROCEDURES AND QUALIFICATION TEST REPORTS
6
5 TO 8
+
9
DESTRUCTIVE AND NON-DESTRUCTIVE TEST REPORTS
6
AS PER INSPECTION PROCEDURE
+
10
RADIOGRAPHIC EXAMINATION REPORTS WITH FILMS
+
II
HEAT TREATMENT CHARTS
+
12
CODE CERTIFICATES (INCLUDING INSPECTION CERTIFICATE, HYDROSTATIC
VENDOR TO STORE THESE FOR 5 YEARS 6
AS PER INSPECTION PROCEDURE
6
AS PER INSPECTION PROCEDURE
TEST CERTIFICATE. LOCAL CODE REQUIREMENTS. RUBBING OF CODE STAMP AND NAME PLATE ETC.)
A
13
ASSEMBLY AND INSTALLATION DETAILS
2
6
8 TO 10
@
14
ERECTION PROCEDURE. ERECTION DRAWINGS (INCLUDING WEIGHTS. CENTER
2
6
8 TO 10
2
6
TWO WEEKS AFTER DESPATCH OF EQPT.
2-
6 (Min.)
TWO WEEKS AFTER DESPATCH OF EQPT.
•• «
OF GRAVITY AND SUNGING FACILITIES ETC.) +
15
CERTIFIED 'AS BUILT DRAWINGS INCORPORATING ACTUAL DIMENSIONS
AND MATERIAL USED. DULY CERTIFIED BY THE INSPECTOR +
.
16
DATA FOLDER AS PER TENDER/SPECIFICATIONS (INCLUDING AS BUILT DRGS.)
17
DRAWING INDEX
6
WITH EACH TRANSMITTAL
18
TECH.SPEC. OF BOUGHOUT ITEMS SUCH AS PLATE, PIPE FORGINGS ETC.
6
BEFORE ORDERING
LEGEND :
*
SHALL BE REVIEWED BY ELL BEFORE FABRICATION. SHALL BE APPROVED BY INSPECTOR. SHALL BE APPROVED BY ELL BEFORE SHIPMENT SHALL BE SUBMITTED FOR INFORMATION ONLY AND HIGHLIGHTING AREAS OF DISCREPANC OR FOULING ETC. ** SHALL BE SUBMITTED TO ELL-SITE + @ P
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NOTES : FOR VENDOR DATA REQUIREMENTS : 1.
FOLD PRINTS TO 210 MM X 297 MM SIZE AND ROLL TRANSPARENCIES.
2.
FABRICATOR TO MAIL DOCUMENTS AS PER FOLLOWING : (ADDRESS AS PER PURCHASE
ORDER). ALL PRINTED MATTER, TRANSPARENCIES AND DATA FOLDER TO: “National Aluminium Company Limited, Smelter Plant” 3.
ALL TRANSPARENCIES SHALL BE ON VERY GOOD QUALITY POLYESTER FILM SEPIA AND MUST BE CAPABLE OF PRODUCING LEGIBLE PRINTS.
4.
EVERY DOCUMENT SHALL BEAR DOCUMENT NUMBER AND REVISION NUMBER. THE NUMBER TO BE UPTO A MAXIMUM OF 28 CHARACTERS IN LENGTH.
5.
THE DRAWING/DOCUMENT SUBMITTED MUST BE CHECKED AND SIGNED/STAMPED BY CONTRACTOR BEFORE IT IS SUBMITTED TO NALCO.
6. REVISION NUMBER MUST CHANGE DURING SUBSEQUENT SUBMISSION OF VENDOR DOCUMENT. 7.
MULTI SHEET DOCUMENTS OTHER THAN DRAWINGS MUST BE SUBMITTED IN THEIR ENTIRETY IN THE EVENT OF A RE-SUBMISSION EVEN IF ONLY A FEW SHEETS ARE REVISED.
8.
ENGLISH LANGUAGE & METRIC UNITS SHALL BE USED IN ALL DOCUMENTS.
SMELTER DIVISION
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STANDARD SPECIFICATION OF STORAGE TANKS FOR PACKAGE ITEMS
SMELTER DIVISION
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CONTENTS
SMELTER DIVISION
1.
GENERAL
2.
CODES AND STANDARDS
3.
DESIGN BASIS
4.
APPURTENANCES AND ACCESSORIES
5.
MATERIAL SPECIFICATION
6.
WELDING CONSUMABLES
7.
FABRICATION AND ERECTION
8.
INSPECTION AND TESTING
9.
TOLERANCES
10.
CALIBRATION
11.
PAINTING
12.
GUARANTEE
13.
DATA FOLDER
14.
LIST OF ATTACHMENTS •
DATA SHEET FOR TANKS (BY VENDOR)
•
VENDOR DATA REQUIREMENTS.
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3.3
Allowable Stresses
3.3.1
Basic allowable stresses for shell, roof etc. shall be the values specified in the design code.
3.3.2
The allowable stresses for structural members and anchor bolts shall be as specified in Indian Standard IS:800.'
3.4
Wind and seismic loads
3.4.1
Wind load shall be calculated as per Indian Standard IS: 875 Fig. 1A.
3.4.2
Earthquake forces shall be calculated in accordance with Indian Standard IS: 1893 OR it shall be based on meteorological and seismic data of the plant site, if attached with tender documents.
3.5
Corrosion Protection
3.5.1
The corrosion allowance for each tank shall be as given in tank data sheet attached with the package. Otherwise it shall be determined by its intended service conditions and service life, (min. 2mm) separately for shell, bottom and roof plates. Corrosion allowance shall be added to these surfaces and to internal parts exposed to the medium. Components made of corrosion resistant material do not require corrosion allowance. Internal roof support structure shall not be provided with any corrosion allowance. It shall be painted as per the provisions of painting specification. Removable internal parts, bolted or clamped in place, shall have extra thickness equal to specified corrosion allowance over the minimum required thickness.
3.5.2
If the internal surface of the tank is to be rubber lined, brief description of lining shall be submitted by Vendor along with the offer.
3.6
The roofs shall be self supported or supported by structure. The roof and supporting structure shall be designed to carry the dead loads and live loads as specified in the tank data sheets and the, design code. Roof plates shall not be attached to the supporting members but well supported on it. The roof structure shall generally be as per Standard. All parts of the structure shall be so designed that the maximum stresses do not exceed the permissible stresses given in IS:800.
3.7
Roof to shell joint shall be frangible type. Otherwise, suitable emergency venting devices shall be provided as per design code.
3.8
For tanks supported on piers above grade, the distance between the pier centers shall preferably be less than 900mm. The deflection in the bottom plate shall be less than half of the plate thickness.
SMELTER DIVISION
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4.0
APPURTENANCES AND ACCESSORIES
4.1
Shell Manholes Minimum number of shell manholes shall be as given below:i)
Tanks with diameter 12M and below : 1 No.
ii)
Tanks with diameter 12.1 M to 40M : 2 Nos.
iii)
Tanks with diameter 40.1 M to 60M : 3 Nos.
Shell manholes shall be 600mm NB unless specified otherwise. 4.2
Roof Manholes Minimum number of roof manholes shall be as given below:1)
Tanks with diameter 30M and below : 1 No.
2)
Tanks with diameter more than 30M : 2 Nos.
Roof manholes shall be 500mm NB unless specified otherwise. 4.3
Platforms and Stairways Tanks with instruments/devices located on the roof shall be provided with platform on roof (minimum 1.2 x 0.8M, size). Platform shall be sized and located so as to permit easy access to those items. Primary access to roof shall be by means of cage ladders for tanks with height upto 6M and by spiral stairways for tanks with height more than 6M. Intermediate landings shall be provided for spiral stairways, preferably at every 5M interval. Hand railing shall be provided at around the tank roof, to enclose platforms end. stairways from both sides.
4.4
Other Accessories All tanks shall be provided with venting device, level indicators and earthing connections. A gauge hatch with cover, for gauging and sampling purposes is to be provided on the tank, if specified on tank data sheet.
5.
MATERIAL SPECIFICATION
5.1
All materials shall be as per applicable codes/Standards. Material test certificates/documents shall be submitted to Inspector for verification.
5.2
Plate material conforming to IS: 226 shall be used upto 20mm thickness, beyond which, IS: 2062 shall be used. Plates shall be in killed or semi killed condition, shall have under tolerance on thickness limited to 0.25mm and shall be guaranteed for wettability. Product analysis of each heat shall be carried out.
5.3
Manhole necks and nozzle necks of 250mm NB and above may be fabricated from same plate material as used for shell.
SMELTER DIVISION
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and painted with 2 coats of epoxy Zinc Chromate primer by the contractor. Inside of roof and roof support structure shall be painted with 2 coats of epoxy red oxide Zinc Phosphate primer.
12.
GUARANTEE The contractor shall guarantee the tanks for design, materials and workmanship. as per the Genera! Conditions of contract/special conditions of contract attached. with the package. Otherwise, guarantee shall be as follows: Any part of tank found defective within 18 months of completion or during 12 months operation, whichever is earlier, and not having been subjected to faulty manipulation or wrong service conditions, shall be promptly repaired/replaced and reassembled by the contractor at his own cost, failing which, the owner has the right to get the same replaced/repaired by others and charge the cost incurred to the contractor.
13.
DATA FOLDER After completion of the job, the contractor shall supply 6 copies of data folder containing the following data: Code compliance certificate, design calculations, "As Built" drawings of the tank, material test certificate, heat treatment report if any, final inspection and test certificate. In addition, one microfilm containing the design calculations and as built drawings of the tank shall be supplied by contractor.
SMELTER DIVISION
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7.
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FORM NO. 1655 DATA SHEET FOR TANKS (TO BE COMPLETED BY ORIGINATING DEPTT.)
DATA SHEET FOR TANKS (TO BE COMPLETED BY VENDOR) Project ....................................... Client
....................................
Unit .......................…………………. Job No......................................^ .... Package.................. : ................... MR No.- ............................... : ...... Equipment.................................... Item No .................................... Code for Design & Construction ............. Design Pressure .............................. Operating Pressure......................... Design Temperature.......................... Operating Temperature.................... Stored Product................................ Specific Gravity ............................ Nominal Capacity............................. Corrosion allowance for shell, bottom, roof........................ Diameter ...................................... Height ...................................... Materials Shell, bottom & roof........................
Manhole neck & flanges ....................
Nozzle necks.................................. Nozzle flanges .............................. Accessories: A list of accessories like caged ladder/spiral stairway, landing platform, level indicator, gauging/sampling device etc. proposed by Vendor should be submitted. — •
Special Lining - if any.
—
Heating Coil
—
Calibration of Tank Note
Vendor shall submit the completed data sheet along with the offer.
SMELTER DIVISION
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VENDOR DATA REQUIREMENTS SI.
Description
No.
No. of sets
No. of sets after
with the bids
placement of order Transparency
Prints
1.
Data sheet for tank
6
2.
Mechanical Design Calculations
-
3.
General arrangement drg., giving dimensions, thickness, nozzles and internal parts along with orientation and material specification.
6 design data, basic
4.
Details of shell, bottom and roof and roof structure showing their welds, nozzles and manhole connections, internals etc.
6
5.
Details of platform, ladder and other accessories.
6
Material test certificates for plates, pipes and flanges.
4
Welding procedure and welder's Qualification reports.
4
6.
7.
-
4
8. . Radiographic test reports (Films to be stored for 5 years)
4
9.
Heat Treatment Report
4
10.
Final Inspection certificate and Hydrostatic test certificate
4-
11.
Final 'As Built* drawings (covering SI. No. 3 & 4) for information.
NOTE 1.
Items at SI. No. 2, 3, 4, 5 are required for review by NALCO.
NOTE 2.
Items at SI. No. 6 to 10 are required by Inspection Agency.
NOTE 3.
All transparencies shall be on polyester film.
SMELTER DIVISION
6•
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STANDARD SPECIFICATION OF PRESSURE VESSELS FOR PACKAGE ITEMS
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CONTENTS
1.
SCOPE
2.
CODE - SPECIFICATIONS - REGULATIONS
3.
DESIGN BASIS
4.
MATERIALS
5.
HEADS
6.
MANHOLES/HANDHOLES AND NOZZLES
7.
FLANGES
8.
INSPECTION
9.
PRESSURE TESTING
10.
WELDING
11.
POST WELD HEAT TREATMENT
12.
RADIOGRAPHY/NON-DESTRUCTIVE TESTING
13.
FIRE PROOFING AND INSULATION
14.
CLEANING AND PAINTING
15.
GENERAL
16.
LIST OF ATTACHMENTS (APPLICABLE STANDARDS AND SPECIFICATIONS) ANNEXURE
SMELTER DIVISION
I)
Vendor Data Requirement
II)
Data of vessel (To be filled in by Vendor)
III)
Material Selection
IV)
Tall Column Design Philosophy
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1.0
SCOPE
1.1
This specification covers general requirements for material design, fabrication, erection and testing of pressure vessels.
1.2
Vessel Sizing/Designing shall be in vendor's scope unless otherwise specified. Vendor shall submit all design parameters of vessels as per Annexure-II.
2.0
CODE - SPECIFICATION - REGULATIONS
2.1
Design Codes
2.2
a)
Vessels with design pressure > 1.0 Kg./Cm2(g) and less than 210 Kg./cm2(g) shall be designed fabricated, inspected and tested as per ASME Code Sec. VIIIDiv.l. (latest)
b)
All vessels with design pressure S 210 Kg./cm2(g) shall be designed, fabricated, inspected and tested as per ASME Code Sec. VIII Div.2. (latest)
c)
Vessels full of liquid and/or with design pressure < 1.0 Kg./cm2(g) shall be designed, fabricated, inspected as per ASME Code Sec. VIII Div.l Practice.
d)
Mechanical design of self-supporting tali column shall be carried out as per guidelines given in Annexure-IV.
Material Specifications Materials to be used shall conform to
2.3
a)
ASME Section II.
b)
Indian Standard Specification of equivalent grade.
Statutory Regulations a)
National laws & regulations together with local byelaws for the country or state where vessel(s) is (are) to be erected must be complied with. Approval of design, drawings from statutory authorities shall be Vendor's responsibility.
b)
Wind and earthquake loads shall be calculated in accordance with relevant Indian Standards unless otherwise specified.
3.0
DESIGN BASIS
3.1
Vessel shell and heads shall have minimum wall thickness calculated with design pressure and temperature, in accordance with codes, but in no case, shall the thickness be less man that determined by following formulas : a)
For carbon and low alloy steel vessels - 6mm (Including corrosion allowance not exceeding 3.0 mm), but not less than that calculated as per following : FOR DIAMETERS LESS THAN 2400 mm
SMELTER DIVISION
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Wall thickness =
Dia. + 1.5 + Corrosion Allowance 1000
FOR DIAMETERS 2400 mm AND ABOVE Wall thickness =
Dia. + 2.5 + Corrosion Allowance 1000
All dimensions are in mm. b)
For stainless steel vessels and high alloy vessels - 3 mm, but not less than that calculated as per following for diameter more than 1500mm. Wall thickness (mm) =
Dia. +2.5 1000
Corrosion allowance, if any, shall be added to minimum thickness. c)
If the vessel height (H) from base of skirt to top tangent line is greater than 5 times diameter (D) then vessel shall be considered as column and shall be designed accordingly.
d)
For carbon and low alloy steel columns/towers - 8mm (including corrosion allowance not exceeding 3.0 mm)
e)
For stainless steel and high alloy columns/towers - 5 mm. Corrosion allowance, if any, shall be added to minimum thickness.
3.2
Design Pressure a)
When-operating pressure is upto 70 Kg./cm2 (g) the design pressure shall be equal to maximum operating pressure at top of vessel or highest point in vessel plus 10% ( minimum of 1.0 Kg./cm2) more than operating pressure. When operating pressure is over 70 Kg./cm2 (g), the design pressure shall be equal to operating pressure plus 5% (minimum 7 Kg./cm2).
3.3
SMELTER DIVISION
b)
Design pressure at any lower point is to be determined by adding the maximum operating liquid head and any gradient within the vessel.
c)
Vessel operating under vacuum (or partial vacuum) shall be designed for external pressure of 1.055 Kg./cm2 (g).
Design Temperature a)
For vessels operating at 0°C and over, the design temperature shall be operating temperature plus 15 °C. However higher design temperature shall not be less than 65 °C.
b)
For vessel operating below 0°C, design temperature shall be lowest operating temperature.
c)
Minimum Design Metal Temperature (MDMT) shall be lower of minimum atmospheric temperature and lowest operating temperature. DOCUMENT TITLE
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3.4
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Corrosion Allowance Minimum corrosion allowance for carbon steel vessels shall be 3.0 mm unless otherwise specified in material requisition.
4.0
MATERIALS Materials of various parts of equipment shall be selected as per Table given in Annexure - III for general industrial condition/services.
4.1
Specifications of Carbon Steel Plates
4.1.1
Chemical Analysis Plates used shall conform to latest issue of specification SA-20 with additional requirements mentioned herein. a)
Only normalised plates free from injurious defects with workman like finish shall be used. Reconditioning/repair of plates by welding shall not be permitted.
b)
One product analysis of each heat shall be carried out and reported. Chemical analysis shall be as per applicable specifications with carbon content not exceeding 0.23%. Additionally one of following requirements for carbon equivalents (Ceq.) based on heat analysis shall be satisfied. Ceq
= C + Mn/6 <. 0.42 Ceq
...(1)
= C + Mn/6+(Cr + Mo + V)5+(Cu+Ni)/15 < 0.43
...(2)
Equation -(1) shall be used when applicable material specify C and Mn only. Equation -(2) is applicable for restricted chemistry requirements or for supplementary requirements of S19 & S21 of SA-20. 4.1.2
4.1.3
Ultrasonic Examinations of Plates a)
Plates having thickness 15 mm to 50 mm (both inclusive) shall be examined ultrasonically as per SA-435.
b)
For thickness above 50 mm, ultrasonic examinations shall be carried out as per SA-578 and shall have acceptance standard of level-I.
c)
For quenched and tempered steel plate ultrasonic examination shall be carried out after the specified heat treatment.
Simulated Heat Treatment of Test Coupons For Plates above 16 mm thickness intended for hot rolling/forming.
SMELTER DIVISION
One normalising* + one stress reliving as per UCS-56 of ASME Code. Sec. VIII Div. 1
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*
Recommended Normalising Cycle :
(i)
Soaking Temperature
900°C To 1000°C
(ii) Holding time one hour per 25 mm thickness but not less than half an hour (iii)
Cooling in still air
4.1.4
Charpy V-notch impact testing as per S5 of SA-20 to be carried out at design temperature for low temperature services.
4.1.5
Plates needed for IBR vessels shall meet the requirements of IBR (Indian Boiler Regulation).
4.1.6
Plates above 50 mm in thickness shall meet following 'additional requirements': Vacuum treatment'as per supplementary requirement S1 of specification SA-2J& Charpy V-notch test as per the supplementary requirement S5 of specification SA-20. Material meant to be used for design temperature warmer than 0°C. Test temperature
-
minus 29°C.
Acceptable Criteria
-
As per Table A 2.15 of SA-20.
Orientation of test bar
-
Transverse to the direction of filling.
Bend test as per supplementary requirement S14 of specification SA-20. Simulated heat treatment of mechanical test coupon as per clause 4.1.3.
4.2
Specification of Stainless Steel Plates/Pipe/Forging Plates used shall conform to latest issue of specification SA-480 with additional requirements mentioned herein.
SMELTER DIVISION
a)
All plates shall be hot rolled, annealed, pickled and shall have No. 1 finish on both sides with reference to SA-480.
b)
Plates, pipes, forgings and fittings representative of each heat shall be subjected to inter granular corrosion tests as per ASTM A 262 practice B for all the 300 series material with acceptance criteria of corrosion rate equal to 48 mils/year.
c)
Plates having thickness 16mm to 50mm (both inclusive) shall be examined ultrasonically as per SA-435.
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For thickness above 50 mm, ultrasonic examinations shall be carried out as per SA-578 and shall have acceptance standard of level-I.
d)
4.3
Six copies of certificates and documents of all tests required here, duly certified by inspecting authority are to be submitted to NALCO inspector before fabrication of vessel. Material Certificates shall conform to DIN 500049 Type 3. IB.
4.4
Material for Internal Lining/Painting a)
FRP Lining i)
Wherever FRP lining on inside of equipment is specified the resin used shall be vinyl ester, equivalent or better to suit the intended service.
ii) The steel surface shall be abrasive blasted as per SSPC-SP-10 and anchor profile of surface shall be 38 to 75 micron. Primer coat of polyamide cured epoxy (25 to 75 micron DFT) shall be immediately applied after cleaning to prevent rust formation before application of FRP lining. Rubber Lining
b)
Application of rubber lining on inside of vessels, shall be done as per IS 4682. Part-I. c)
Painting on Internal Surface Surface preparation and application of Primer and Painting shall be in accordance with specification in this document.
5.0
HEADS a)
Heads shape, dimensions proposed by the manufacturer must be stated in offer. All carbon steel dished heads and toricones upto 16mm thickness (nominal) shall be stress relieved and more than 16mm thickness shall be normalised if cold pressed or formed. However, in case, hot forming is carried out in the normalising range, no stress relieving is necessary.
b)
Cold formed dished ends of SS Vessels shall not be solution annealed unless any of the following condition exists: i)
Specifically called for particular equipment/service.
ii)
Hardness value after forming exceeds 235 BHN.
iii)
Nominal thickness of plate is 16mm or above. Hot formed dished ends of SS Vessels shall be solution annealed.
6.0
MANHOLES/HANDHOLES AND NOZZLES a)
Manholes shall be minimum 457 mm NB unless otherwise specified.
b)
Manhole cover shall be provided with a davit or hinge.
SMELTER DIVISION
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c)
Small vessels shall be provided with two pad type inspection opening of 150 NB. If it is not possible for small vessel upto 300 diameter vessel a suitable spool pipe shall be provided in the piping for inspection.
d)
For vessels with diameter less than 900mm and having removable internals, shell flanges shall be provided.
e)
The reinforcement for the nozzles opening shall be integral type when required by the applicable code/standards or when the thickness of vessel wall exceeds 50mm. Self-reinforcement type nozzles 80NB and above shall be set-in type. i
7.0
8.0
FLANGES a)
All flanges shall be as per ANSI B-16.5. Larger flanges not covered by ANSI B16.5 shall be to ANSI B: 16.47 (Series B).
b)
For nozzles 100 NB and below, only weldneck flanges to be used. Slip on flanges may be used for nozzles above 100 NB for class 150 flanges only.
c)
Only weldneck flanges shall be used in hydrogen service, cyclic service and corrosive services where corrosion allowances is in excess of 3.0mm.
d)
All flanges above class 150 lbs should be weldneck type.
e)
All flanges of class 900 and above shall have gasket surfaces for RTJ.
INSPECTION All vessels shall be offered for stage-wise as well as for final inspection to Purchaser or his authorized inspector. Inspector shall have free access to all workshops of vendor or his sub-vendors.
9.0
PRESSURE TESTING All vessels shall be hydrostatically or pneumatically tested as per the code. Necessary precaution shall be taken to guard against the risk of brittle fracture during hydrostatic test. Test water temperature shall not be lower than 15 °C plus MDMT of the vessel.
10.0
WELDING Full penetration weld shall be employed for joining pressure parts. Where both sides are not accessible for welding, root run by tungsten inert gas process or backing strip may be used to ensure full penetration. Backing strip, if used, is to be removed after welding, wherever possible.
11.0
POST WELD HEAT TREATMENT a)
SMELTER DIVISION
Vessels shall be heat-treated whenever it is .required due to service requirement or due to code requirements. Vessels shall be post weld-heat
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treated as a complete unit and no welding shall be permitted once post weld heat treatment is performed. b)
Wherever heat treatment on stainless steel is carried out, it shall be followed by micro etching test and IGC test as per ASTM A 262 Practice B with acceptance criteria of corrosion rate equal to 48 mils/year to ascertain suitability and effectiveness of solution annealing.
12.0
RADIOGRAPHY/NON DESTRUCTIVE TESTING
12.1
The extent of radiography shall be as specified on the engineering drawings. In no case shall the radiographic examination be less than that specified in the code. However, spot radiography is the minimum requirement for all vessels.
12.2
When spot radiography is specified, the following requirements shall supplement the requirements specified in ASME Section VIII Division I : (i)
All T joints shall be radiographed.
(ii) Minimum 5% of total weld length excluding T joints shall be radiographed. 12.3
All nozzles fabricated from plate, irrespective of thickness of plate, shall be 100% radiographed.
12.4
Weld seams of formed ends shall be 100% radiographed after forming and heat treatment, if any.
12.5
The technique employed and the weld quality achieved shall meet the requirement of the code.
12.6
All nozzle to shell welds (Root and Final run) shall be examined by magnetic panicle/Dye penetrant test.
13.0
FIRE PROOFING AND INSULATION Vessels requiring insulation and/or fireproofing shall be provided with supports as per NALCO standard attached to this specification.
14.0
CLEANING AND PAINTING a)
Vessels shall be cleaned internally to remove scale, rust, dirt, and foreign material by wire brushing.
b)
Stainless steel surfaces both inside and outside shall be pickled and passivated in accordance with ASTM-A380 after hydrotest.
c)
All external surfaces shall be cleaned, primed and painted in accordance with 6-44-04 for specified environment.
15.0
GENERAL
15.1
Vessel weighing more than 5.0 MT shall be provided with lifting lugs.
SMELTER DIVISION
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15.2
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Manufacturer shall supply spares as given below : Gaskets
:
Two sets for each installed gasket.
Fasteners
:
10% (minimum two in each size) of installed fasteners.
Sight/Light glass
4 Sets for each installed glass.
15.3
Fabrication tolerances indicated in Standards/Specifications shall be adhered to.
15.4
Nozzles upto 50 NB size shall be stiffened with 2 number of 40 wide x 6 thick stiffeners welded at 90° apart.
15.5
Vessel diameter-300 NB and below shall be made from seamless pipe only.
15.6
Nozzle connections used for vessels shall not be less than 40NB.
15.7
Rolling direction for making shell shall be lengthwise.
Guarantee, packing, marking on vessels and shipment, etc. to be as per package specifications.
SMELTER DIVISION
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ANNEXURE-I
VENDOR DATA REQUIREMENT S.NO.
NO. OF
WITH
AFTER
AFTER
COPIES REQD.
PROPOSAL
ORDER PLACEMENT FOR REVIEW/ APPROVAL
FABRICATION OF EQUIPMENT WITH DATA FOLDER
DATA SHEET FOR PRESSURE VESSEL
4
REQUIRED
REQUIRED
MECHANICAL DESIGN CALCULATIONS
4
ONE VESSEL TYPICAL
REQUIRED
NOT REQUIRED
2.
GENERAL ARRANGEMENT DRAWING OF EQPT. ALONG WITH ORIENTATION AND DESIGN PARAMETERS AND SPECIAL NOTES REGARDING DESIGN/FABRICATION/ TESTING PROCEDURES, DRAWING INDEX ETC.
4
NOT REQUIRED
REQUIRED
REQUIRED
3.
EQUIPMENT FABRICATION DRAWING WITH MATERIAL SPECIFICATIONS SHOWING ALL MAIN WELDS, NOZZLES MANHOLE DETAILS INTERNALS AND OTHER ACCESSORIES
4
NOT REQUIRED
REQUIRED
REQUIRED
4.
MATERIAL TEST AND
6
NOT
REQUIRED
REQUIRED
REQUIRED
BY INSPECTION AGENCY
NOT
REQUIRED
REQUIRED
BY INSPECTION AGENCY
a) b)
DESCRIPTION
ANALYSIS CERTIFICATES 5.
WELDING PROCEDURE QUALIFICATION, WELDERS .-?■ QUALIFICATION ' REPORTS, ULTRASONIC, MP/DP TEST, CHARPY 'VNOTCH TEST, HYDROTEST, RECORDS, RADIOGRAPHY REPORTS AND PWHT CHARTS
6
!
-
REQUIRED
ANNEXURE – II
SMELTER DIVISION
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DATA SHEET FOR PRESSURE VESSEL (To be filled in by the Vendor)
PROJECT
CLIENT
UNIT
JOB NO.
ITEM NO.
PACKAGE
EQUIPMENT
MR. NO.
CODE FOR DESIGN AND CONSTRUCTION DESIGN CONDITION
OPERATING CONDITIONS
PRESSURE (Kg./cmzg)
PRESSURE (Kg./cm'G)
TEMPERATURE (°C)
TEMPERATURE (°c)
CORROSION ALLOWANCE SERVICE
H2S [ ] LETHAL [ ] OTHERS
LIQUID LEVEL(mm) SPECIAL SURFACE FINISH INSIDE VESSEL
REQD. [ ] NOT REQD. [ ]
TYPE OF VESSEL
HORIZONTAL [ ] VERTICAL [ ]
DIAMETER (mm)
SKIRT /LEG HEIGHT
HEIGHT TL-TL (mm) JOINT EFFICIENCY
SHELL
HEAD
RADIOGRAPHY
SHELL
HEAD
POST WELD HEAT TREATMENT MATERIALS OF CONSTRUCTION SHELL, REINFORCEMENT PADS HEADS/CONES
NOZZLE NECK
SHELL FLANGES
MAN-WAY NECK
NOZZLE FLANGES
PIPE FITTINGS
INTERNAL PARTS
GASKETS(EXTERNAL)
EXTERNAL STUDS/NUTS
GASKETS (INTERNAL)
INTERNAL BOLTS/NUTS
SKIRT/LEG SUPPORT
CLIP ATTACHMENTS (EXTERNAL) ANY OTHER GENERAL REQUIREMENT NOTE :
SMELTER DIVISION
VENDOR SHALL SUBMIT COMPLETED DATA SHEET ALONG WITH OFFER WHEREVER ENGG. DRAWING IS NOT ATTACHED FOR THE VESSEL.
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ANNEXURE-III MATERIAL SELECTION The following table gives general guidelines for material selection for various Pressure Parts/Non Pressure Parts of the equipment :PRESSURE PARTS DESIGN TEMP.'C
NON PRESSURE PARTS
PLATE
PIPE ISEE NOTE 8)
FORGING
BOLTS/ STUDS/ NUTS EXTERNAL
FROM-254 UPTO-196
SA 240 GR.304L.3O4, 316.316L 347 (IMPACT TESTEDI
SA 312 TYPE 304 304L.316, 316L.347
SA 182.GR F 304.304L.31 6 347,316L
ABOVE-196 UPTO -80
SA 240 GR.304L.304. 316.316L 321,347
SA 312 TYPE 304 304L.316, 316L.321. 347
SA 182.GR F 304.F304L, F316L.316 321.347.
SA 353/553 GR.A
SA 333 GR.8
SA 522
STRUCTURAL ATTACHMENT WELDED TO PRESSURE PARTS
INTERNAL PIPES
STUDS BOLTS NUTS INTERNAL
CRYOGENIC
LOW
SA 320 GR 88.8C.8T STRAIN HARDENED SA 194GR.S, 8C.8T
SAME AS PRESSURE PARTS
TEMPERATURE
ABOVE -80 UPTO -60
SA 203 GR E IMPACT TESTED (SEE NOTE-11
SA 333 GR.3
SA 350 GR.LF3
SA 320 L7 SA 194GR.4 ORGR 7
SA 203 GR E
SA 333 GR.3
SA 193 GR.B8 SA 194 GR.8
ABOVE -60 UPTO -45
SA 537 CL.1 IMPACT TESTEDISEE NOTE-1)
SA333 GR.3
SA 350 GR.LF3
SA 320 L7 SA 194 GR.4 ORGR 7
SA 537 CL.I
SA 333 GR.3
SA 193 GR.B8 SA 194 GR.8
ABOVE -45 UPTO -29
SA 516 (ALL GRADES) IMPACT TESTED (SEE NOTE-I)
SA 333 GR.6 OR GR 1
SA 350 GRLF2
SA 320 GRL7 SA 194 GR.4 ORGR 7
SA-516 (IN ALL GRADES)
SA 333 GR.6
SA 193 GR.B8 SA 194 GR.8
ABOVE -29 UPTO 0
SA 516(ALL GRADES! (SEE NOTE-3)
SA 106 GR.B (SEE NOTE 31
SA 105/ SA 266 (SEE NOTE 3)
SA-193 GR B7 SA194GR 2H
SA-516 (IN ALL GRAOES)
SA 106 GR.B
SA-193 GR.88 SA194 GR.8
INI ABOVE 0 UPTO 343
SA 516 (ALL GRADES!
SA 106 GR.B
ERMEOIATE SA-105 SA-266
TEMPERAT
ORE
SA-193 B7 SA194GR 2H
IS-2062 (PLATES)
SA 106 GR.B
SA-193 GR.B8 SA194 GR.4
SA 182 F 304L.31 6L, 321
SA-193 B7 SA194 GR2H
SAME AS PRESSURE PARTS
SA 106 GR.B
SA-193 GR.B8 SA194 GR.S
1 SA 240 TYPE 304L. 316L.321 (SEE NOTE 4)
ABOVE 343 UPTO 427
SMELTER DIVISION
.-■€A-312 •' "TP 304L 316U321 SA-376 TP321
SA-204 GR.B
SA 335 GR PI
SA 182 GR.F1
SA 193GR.B7 SA 194 GR.4
SAME AS PRESSURE PARTS
SAME AS PRESSURE PARTS
SA-193 GR.B8 SA 194 GR.8
SA387GR.11 CL.1/CL2
SA335 GR.P11
SA 182 GR.F11
SA 193GR.B7 SA 194 GR.4
SAME AS PRESSURE PARTS
SAME AS PRESSURE PARTS
SA-193 GR.B8 SA 194 GR.S
SA 240 TYPE 3041,31 EL, 32 USEE NOTE 4)
SA 312 TYPE 304L.316L. 321 SA 376 TYPE 321
SA 182 F 304L. 316L. 321
SA 193GR.B7 SA 194 GR.4
SAME AS PRESSURE PARTS
SAME AS PRESSURE PARTS
SA-193 GR.B8 SA 194 GR.8
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PRESSURE PARTS DESIGN TEMP.'C
PLATE
PIPE (SEE NOTE 8)
FORGING
ELEVATED
NON PRESSURE PARTS BOLTS/ STUDS/ NUTS (EXTERNAL)
STRUCTURAL ATTACHMENT WELDED TO PRESSURE PARTS
INTERNAL PIPES
STUDS BOLTS NUTS INTERNAL
TEMPERATURE
A80VE 427 UPTO 538
SA 387 GR.11 CL.1/CL.2 SA 387GR.12 CL.I/CL.2
SA 335 P11 SA 335 P12
SA 182 GR F1! SA 182 GR.F12
SA 193 GR.B16 SA 194 GR.4
SAME AS PRESSURE PARTS
SAME AS PRESSURE PARTS
SA-193 GR 88 SA 194 GR.8
ABOVE 427 UPTO 500
SA 240 TYPE 304,316.321 (SEE NOTE 4]
SA 312/ SA 376 TYPE 304,316. 321
SA 182F 304, 316. 321
SA 193 GR.816 SA 194 GR.4
SAME AS PRESSURE PARTS
SAME AS PRESSURE PARTS
SA-193 GR.B8 SA 194 GR.8
ABOVE 538 UPTO 593
SA 387GR.22 CL.1/CL.2 SA 387 GR.21 CL.1/CL.2
SA 335 P22
SA 182 GR F22 SA 336 GR F22
SA 193 GR B5 SA 194GR.3
SAME AS PRESSURE PARTS
ABOVE 500 UPTO 81 5
SA 240 GR.304H, 316H 321H.
SA 312/ SA 376 TYPE 304H, 316H, 321H
SA 182 GRADES 304H, 316H.321H
SA 193GRB8 SA 194GR.8 (STRAIN HARDENEDI
SAME AS PRESSURE PARTS
NOTES: 1. PRESSURE VESSEL STEEL PLATES ARE PURCHASED TO THE REQUIREMENT OF THE STANDARD ASME SA-20, WHICH REQUIRES TESTING OF INDIVIDUAL PLATES FOR LOW TEMPERATURE SERVICE. CARBON STEEL MATERIAL IS ORDERED TO MEET THE IMPACT REQUIREMENTS OF SUPPLEMENT S5, OF STANDARD ASME SA 20, TYPICAL MATERIAL SPECIFICATION IS AS FOLLOWS SA 516 GR.60. NORMALISED, TO MEET IMPACT REQUIREMENTS PER SUPPLEMENT S5 OF SA 20 AT-50°F. 2. ALL PERMANENT ATTACHMENTS WELDED DIRECTLY TO 9% NICKEL STEEL SHOULD BE OF THE SAME MATERIAL OR OF AN AUSTENITIC STAINLESS STEEL TYPE WHICH CANNOT BE HARDENED BY HEAT TREATMENT. 3. CHECK FOR IMPACT TESTING REQUIREMENT AS PER UCS-66, FOR COINCIDENT TEMPERATURE AND PART THICKNESS. 4. SELECTION OF STAINLESS STEEL MATERIAL SHALL BE BASED ON PROCESS RECOMMENDATION/PROCESS LICENSOR. 5. THIS TABLE IS NOT APPLICABLE FOR ATMOSPHERIC/LOW PRESSURE STORAGE TANKS. MATERIALS SHALL BE SELECTED AS PER API 650/API 620 AS APPLICABLE. 6. MATERIALS FOR CAUSTIC SERVICE, SOUR SERVICE OR SOUR SERVICE + HIC SHALL BE SELECTED BASED ON SPECIFIC RECOMMENDATION OF PROCESS LICENSOR. 7. MATERIAL FOR PRESSURE VESSELS DESIGNED ACCORDING TO ASME SECTION VIII DIVISION 2 SHALL BE GIVEN SPECIAL CONSIDERATION AS PER CODE. 8. ALL PIPES SHALL BE OF SEAMLESS CONSTRUCTION. 9. NON-FERROUS MATERIAL AND SUPER ALLOYS ARE NOT COVERED ABOVE AND SHALL BE SELECTED BASED ON SPECIFIC RECOMMENDATION. 10. MATERIAL FOR VESSEL / COLUMN SKIRT SHALL BE THE SAME MATERIAL AS OF VESSEL / COLUMN SHELL FOR THE UPPER PART WITH A MINIMUM OF 500MM.
SMELTER DIVISION
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ANNEXURE- IV DESIGN PHILOSOPHY OF TALL COLUMNS Mechanical design of self-supporting tall column and its anchorage block shall be carried out considering combination of various loads.
1.0
Loadings The loadings to be considered in designing a self-supporting tall column/tower shall include :
1.1
Internal and or external design pressure specified on process data sheets.
1.2
Self weight of column inclusive of piping, platforms, ladders, manholes, nozzles, trays, welded and removable attachments, insulation and operating liquid etc. The weight of attachments to be considered shall be as per Table-I enclosed. Other loadings as specified in UG-22 of ASME Code Sec. VIII Div.l, wherever applicable.
1.3
Seismic forces and moments shall be computed in accordance with IS 1893 (latest edition). Unless otherwise specified importance factor and damping coefficient shall be considered as 2 and 2% respectively.
1.4
Basic wind pressure and wind velocity (including that due to winds of short duration as in squalls) for the computation of forces/moments and dynamic analysis respectively shall be in accordance with IS 875 (latest edition). Additional wind loading on column due to external attachments like platforms, ladders, piping and attached equipment should be given due consideration.
1.5
Loadings resulting in localized and gross stresses due to attachment or mounting of reflux/reboiler, condenser, etc.
2.0
Loading Condition Analysis shall be carried out for following conditions :
2.1
Erection Condition
2.2
Operating Condition
SMELTER DIVISION
Column (uncorroded) erected on foundation, without insulation, platforms, trays etc. but with welded attachments plus full wind on column. :
Column (in corroded condition) under design pressure, including welded items, trays, removable internals, piping, platforms, ladder, reboiler mounted on column, insulation and operating liquid etc. plus full wind, on insulated column with all other projections open to wind, or earthquake forces.
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STANDARD SPECIFICATION FOR BOILER QUALITY CARBON STEEL PLATES
SMELTER DIVISION
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CONTENTS 1.
SCOPE
2.
GENERAL
3.
SUPPLEMENTARY TECHNICAL REQUIREMENTS
4.
CERTIFIED DOCUMENTS
5.
PAINTING AND COATING
6.
INSPECTION AUTHORITY
SMELTER DIVISION
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1.
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SCOPE This specification covers requirements for carbon steel plates intended primarily for pressure vessels/heat exchangers. The steel plates shall meet the requirements of ASME Boiler and Pressure Vessel Code Section II (latest). This is intended to supplement the minimum applicable requirements of the material specification indicated in the material requisition.
2.
GENERAL
2.1
Plates supplied to this specification shall conform to specification SA-20 with additional requirements mentioned herein.
2.2
The tolerance on thickness of steel plates shall be positive only.
2.3
Final Rolling shall be lengthwise.
2.4
The plates shall be free from injurious defects and shall have workmanlike finish. Reconditioning/repair of plates by welding shall not be permitted. Surface conditions shall meet requirements of EN 10163 Class A Subclass 3.
3.
SUPPLEMENTARY TECHNICAL REQUIREMENTS
3.1
All plates shall be supplied in normalised condition except when the applicable material specifications require supply of plates in quenched and tempered condition.
3.2
a.
One product analysis of each heat shall be carried out and reported. Chemical analysis shall be as per applicable specification.
b.
The carbon content for plates shall not exceed 0.23%. Additionally, one of the following requirements for carbon equivalent based on heat analysis, shall be also satisfied: Ceq = C+Mn/6
...
(Eqn. - 1)
Ceq =C+Mn/6+(Cr+Mo+V)/5+(Cu+Ni)/15
SMELTER DIVISION
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Equation -2 shall be used when applicable material specifies the above elements or restricted chemical requirements are specified or supplementary requirements S19 and S21 of SA-20 are specified in material requisition. 3.3
Ultrasonic Examination of Plates
3.4
a.
Plates having thickness 16 mm to 50 mm (both inclusive) shall be examined ultrasonically as per SA-435.
b.
For thickness above 50mm ultrasonic examination shall be carried out as per SA-578 and shall have acceptance standard of level-1.
c.
For quenched and tempered steel plates, examination shall be done after the heat treatment of plates.
ultrasonic
Simulated Heat Treatment of Test Coupons The following heat treatment shall be conducted on the test coupons representative of heat treated plates before the specified mechanical testing like tensile, bend, impact tests, etc. These details shall also be recorded on the test certificates. Heat Treatment Cycle For plates above 16mm thickness intended for hot rolling/hot forming.
3.5
SMELTER DIVISION
One normalising * + One stress relieving as per UCS-56 of ASME Sec. Vni Div.l.
Note :
Any other special requirement shall be specified in MR.
*
Recommended normalising cycle :
i)
Soaking temperature:
ii)
Holding time one hour per 25 mm thickness but not less than half an hour
iii)
Cooling in still air
900°C to 1000°C
If specified in the material requisition charpy V-notch impact test as per supplementary requirement S5 of specification SA-20 at temperature indicated in the material requisition shall be conducted, for low temperature service. DOCUMENT TITLE
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If specified in the material requisition, plates shall meet the requirements of Indian Boiler Regulations (IBR).
3.6
3.7
Additional requirements for high thickness plates Plates of thickness 50mm and above shall meet following additional requirements :a.
Vacuum Degasing treatment as per requirement SI of specification SA-20.
the
supplementary
b.
Charpy V-notch impact test as per the supplementary requirement S5 of specification SA-20. i) Material meant to be used for design temperature more than 0°C, impact test shall be carried out at (-)29°C and acceptance criteria for energy absorption shall be as per Table A2.15 of SA-20. ii) Acceptance criteria and test temperature for impact testing of non listed material of Table A2.15 of SA-20 shall be as specified in material requisition.
4.
c.
Bend test as per the supplementary requirement S14 of specification SA-20.
d.
Simulated heat treatment of test coupons for all plates as per Clause 3.4 mentioned above.
CERTIFIED DOCUMENTS The supplier shall furnish 6 copies of the following certificates/documents inclusive of all tests required as per specification duly certified by the Inspecting Authority before shipment of plates. The actual values obtained shall be recorded in the test certificates/documents. Material certificates shall conform to DIN 50049 Type 3.IB.
SMELTER DIVISION
a.
Chemical Analysis
b.
Mechanical Tests
c.
Data of heat treatment i.e. initial temperature, heating rate, soaking temperature, cooling rate, etc.
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d.
Simulated Heat Treatment of Mechanical Test coupons (S3 of SA20) at indicated Heat Treatment Cycle (if specified in; the requisition or whenever applicable)
e.
Ultrasonic Examination (S8 or S12 of SA-20)
f.
Charpy V-notch impact tests (S5 of SA-20 if specified in the requisition or whenever applicable)
g.
Bend test (S14 of SA*20 if specified in the requisition or whenever applicable)
h.
Certification as per IBR (if specified in the requisition)
i.
Date of manufacture (final rolling)
j.
SSC and/or HIC tests (if specified in material requisition)
PAINTING AND COATING No painting/coating of any kind is permitted on the steel plates.
6.
INSPECTION AUTHORITY
6.1
Unless otherwise stated in requisition, no third party inspection is required. Material test certificate duly certified by Mill's quality assurance/quality control department is acceptable.
6.2
However, if third party inspection is specified in requisition, all test certificates and documents shall be duly certified by the third party
SMELTER DIVISION
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STANDARD SPECIFICATION FOR STRUCTURAL QUALITY WELDABLE STEEL PLATES FOR TANKS AND VESSELS
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CONTENTS
1.
SCOPE
2.
GENERAL
3.
SUPPLEMENTARY TECHNICAL REQUIREMENTS
4.
CERTIFIED DOCUMENTS
5.
PAINTING AND COATING
6.
INSPECTION AUTHORITY
SMELTER DIVISION
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1.
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SCOPE This specification covers additional and supplementary requirements for Carbon Steel Plates of structural quality to IS:2062 (latest) intended primarily for welded storage tanks and vessels.
2.
GENERAL
2.1
The maximum under tolerance permissible on the plate thickness shall be 0.25 mm. Tolerances on other dimensions of plates shall be as per IS: 1852.
2.2 2.3 2.4
Final rolling shall be lengthwise. Reconditioning/Repair of plates by welding shall not be permitted. Surface condition shall meet requirements of EN 10163 (Part 2) Class A Subclass 3. Invoicing shall be based on theoretical weight (Density 7.85 gm/ce).
3.
SUPPLEMENTARY TECHNICAL REQUIREMENTS
3.1
Heat analysis and product analysis shall be carried out for each heat as per the specification 1S:2062.
3.2
Y-groove weld crackability test as per IS: 10842 shall be carried out for plates conforming to IS:2062 Gr.C having thickness 12mm and above.
3.3
Charpy impact test shall be carried out on the plates conforming to IS.2062 Gr B and Gr C. Test temperature shall be as specified in the Material requisition and acceptance criteria for energy absorption shall be as mentioned in TabIe-2 of the specification IS:2062.
3.4
Simulation Heat Treatment of Test Coupons
3.4.1
Simulation heat treatment of test coupons is required for plates above 25mm thick. For plates of thickness 25mm and less, simulation heat treatment shall be specified in material! requisition.
3.4.2
The heat treatment shall be carried out on test coupons before mechanical testing like bend, tensile, impact, etc. The test coupons shall be drawn from one plate (in each thickness) per heat. Results shall be reported on test certificate along with the heat treatment cycle. Recommended heat cycle is as given below.
SMELTER DIVISION
No. of Cycle
:
One
Holding Temperature
:
594°C to 648°C
Holding Time
:
Minimum one hour per inch of thickness but in no case less than half an hour.
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Furnace Temperature at the Time of Loading
4.
Not to exceed 400°C.
Rate of Heating
:
200°C max./hr.
Rate of Cooling
:
250°C max./hr.
CERTIFIED DOCUMENTS The supplier shall furnish 6 copies of the following certificates/documents inclusive of all tests required as per specification duly certified by the Inspecting Authority before shipment of plates. The actual values obtained shall be recorded in the test certificates/documents. Material certificates shall conform to DIN 50049 Type 3.1 B.
5.
a.
Chemical Analysis
b.
Mechanical Tests
c.
Simulated heat treatment Cycle
d.
Charpy V-notch impact tests
e.
Weldability test
f.
Date of manufacture (final rolling)
PAINTING AND COATING No painting/coating of any kind is permitted on the steel plates.
6.
INSPECTION AUTHORITY
6.1
Unless otherwise stated in requisition, no third party inspection is required. Material test certificate duly certified by Mill's quality assurance/quality control department is acceptable. i
6.2
However, third party inspection is specified in requisition, all test certificates and documents shall be duly certified by the third party.
SMELTER DIVISION
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STANDARD SPECIFICATION FOR STAINLESS STEEL PLATES
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CONTENTS 1.
SCOPE
2.
GENERAL
3.
SUPPLEMENTARY TECHNICAL REQUIREMENTS
4.
CERTIFIED DOCUMENTS
5.
PAINTING AND COATING
6.
INSPECTION AUTHORITY
SMELTER DIVISION
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SCOPE This specification covers requirements for chromium, chromium-nickel and chromium-manganese-nickel stainless and heat resisting steel plates intended primarily for pressure vessels/heat exchangers. The steel plates shall meet the requirements of ASME Boiler and Pressure Vessel Code Section II (latest). This is intended to supplement the minimum applicable requirements of the material specification indicated in the • material requisition.
2.
GENERAL
2.1
Plates supplied to this specification shall conform to specification SA480 with additional requirements mentioned herein.
2.2
Plate length and width provide tolerance for shear and plasma cutting only. The tolerance on thickness of plates shall be positive only.
2.3
Final Rolling shall be lengthwise.
2.4
Plate shall have no. 1 finish on both sides with reference to SA-480.
3.
SUPPLEMENTARY TECHNICAL REQUIREMENTS All plates shall be supplied in hot-rolled, annealed and pickled
3.1 condition.
Plate representative of each heat shall be subjected to intergranular corrosion tests as per ASTM A-262 Practice B for all the 300 series materials with acceptance criteria of corrosion rate equal to 48 mils/year.
3.2
3.3 b.
a.
Plate having thickness 16 mm to 50 mm (both inclusive) shall be examined ultrasonically as per SA-435. For thickness above 50mm ultrasonic examination shall be carried out as per SA-578 and shall have acceptance standard of level-1.
3.4
All mandatory tests as per material specification shall be carried out. However tension test specimen shall be from finished material and shall be selected in transverse direction.
4.
CERTIFIED DOCUMENTS The supplier shall furnish 6 copies of the following certificates/documents inclusive of all tests required as per specification duly certified by the Inspecting Authority before shipment of plates. The actual values obtained shall be recorded in the test
SMELTER DIVISION
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certificates/documents. Material certificates shall conform to DIN 50049 Type 3.IB.
5.
a.
Chemical Analysis
b.
Mechanical Tests
c.
Data of heat treatment i.e. initial temperature, heating rate, soaking temperature, cooling rate, etc.
d.
Ultrasonic Examination
e.
Intergranular corrosion test for 300 series
f.
Intergranular corrosion test for series other than 300 (whenever specified in the requisition)
g.
Type of finish for plate surfaces
h.
Date of manufacture (final rolling)
PAINTING AND COATING Plates are not to be painted/coated but shall be covered with plastic foils or paper or by other means for careful protection and shall be packed against any damage during transit and sea-weather conditions.
6.
INSPECTION AUTHORITY
6.1
Unless otherwise stated in requisition, no third party inspection is required. Material test certificate duly certified by Mill's quality assurance/quality control department is acceptable.
6.2
However, if third party inspection is specified in requisition, all test certificates and documents shall be duly certified by the third party.
SMELTER DIVISION
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STANDARD SPECIFICATION FOR SHOP & FIELD PAINTING
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GENERAL
1.1
These technical specifications shall be applicable for the work covered by the contract, and without prejudice to the various codes of practice, standard specifications etc. It is understood that contractor shall complete the work in all respects with the best quality of materials and workmanship and in accordance with the best engineering practice and instructions of Engineer-in-charge.
1.2
Wherever it is stated in the specification that a specific Material is to be supplied or a specific work is to be done, it shall be deemed that the same shall be supplied or carried out by the contractor. Any deviation from this standard without written deviation permit from appropriate authority will result in rejection of job.
2.0
SCOPE Scope of work covered in the specification shall include, but not limited to the following. 2.1
This specification defines the requirements for surface preparation, selection and application of paints on external surfaces of equipment, vessels, machinery, piping, ducts, steel structures, external & internal protection of storage tanks for all services, RCC Chimney & MS Chimney with or without Refractory lining and Flare lines etc.
2.2
Extent of Works
2.2.1 The following surfaces and materials shall require shop, pre-erection and field painting: a. All uninsulated C.S. & A.S. equipment like columns, vessels, drums, storage tanks, heat exchangers, pumps, compressors, electrical panels and motors etc. i
b.
All uninsulated carbon and low alloy piping fittings and valves (including painting of identification marks), furnace, ducts and stacks.
c.
All items contained in a package unit as necessary.
d.
All structural steel work, pipe, structural steel supports, walkways, handrails, ladders, platforms etc.
e.
RCC/MS chimneys with or without refractory lining & Flare lines.
f.
Identification colour bands on all piping as required including insulated Aluminium clad, galvanized, SS and non-ferrous piping.
SMELTER DIVISION
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Identification lettering / numbering on all painted surfaces of equipment piping insulated Aluminium clad, galvanized, SS and non-ferrous piping.
h.
Marking / identification signs on painted surfaces of equipment / piping for Hazardous service.
i. Supply of all primers, paints and all other materials required for painting other than Owner's supply. j.
Over insulation surface of equipments and pipes wherever required.
k.
Painting under insulation for carbon steel and stainless steel as
specified. 1.
Repair work of damaged / pre-erection / fabrication shop primer and
weld joints at field. 2.2.2 The following surfaces and materials shall not be painted unless otherwise specified: a. b. c.
2.3
Uninsulated austenitic stainless steel. Plastic / or plastic coated materials. Non ferrous materials like Aluminium, Galvanized "piping", "gratings" and "Handrails" etc. except G.I. Towers.
Documents
2.3.1 The contractor shall perform the work in accordance with the following documents issued to him for execution of work. I I a. Bill of quantities for Piping, equipment, machinery and structures etc. b.
Piping Line List.
c.
Painting specifications including special civil defence requirement
2.4 Unless otherwise instructed final painting on pre-erection / shop primed pipes and equipments shall be painted in the field, only after mechanical completion and testing on system are completed, as well as, after completion of steam purging wherever required.
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2.5 Changes and deviations required for any specific job due to client’s requirement or otherwise shall be referred to NALCO for deviation permit. 3.0
CODES & STANDARDS
Without prejudice to the provision of Clause 1.1 above and the detailed specifications of the contract, the following codes and standards shall be followed for the work covered by this contract. IS:5
:
Colour coding
IS-101
:
Methods of test for ready mixed paints and enamel
IS-2379:1990 Colour
:
Indian Standard for Pipeline identificationCode.
ASTM paints and
:
American Standard test methods for coatings.
ASA A 13.1-1981 American
:
Scheme for Identification of piping systems : National Standards Institution.
3.2
Surface Preparation Standards: Following standards shall be followed for surface preparations:
3.2.1 Swedish Standard : SIS-05 5900-1967 / ISO-8501-1-1988 (Surface preparations standards for Painting Steel Surfaces). This standard contains photographs of the various standards on four different degrees of rusted steel and as such is preferable for inspection purpose by the Engineer-in-Charge. 3.2.2 Steel Structures Painting Specifications(SSPC-SP).
Council,
U.S.A.(Surface
Preparation
3.2.3 British Standards (Surface Finish or Blast-cleaned for Painting) BS-4232. 3.2.4 National Association of Corrosion Engineers, U.S.A.(NACE) 3.2.5 Various International Standards equivalent to Swedish Standard for surface preparation are given in Table-I.
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3.3
The contractor shall arrange, at his own cost, to keep a set of latest edition of any one of the above standards and codes at site.
3.4
The paint manufacturer's, instructions shall be followed as far as practicable at all times. Particular attention shall be paid to the following: a.
Instructions for storage to avoid exposure as well as extremes of
temperature.
4.0
b.
Surface preparation prior to painting.
c.
Mixing and thinning.
d.
Application of paints and the recommended limit on time intervals between coats.
EQUIPMENT
4.1 All tools, brushes, rollers, spray guns, abrasive material, hand / power tools for cleaning and all equipments, scaffolding materials, shot / wet abrasive blasting, water blasting equipments & air compressors etc. required to be used shall be suitable for the work and all in good order and shall be arranged by the contractor, at site and in sufficient quantity. 4.2 Mechanical mixing shall be used for paint mixing operations in case of two pack systems except that the Engineer-in-Charge may allow the hand mixing of small quantities at his discretion. 5.0
5.1
SURFACE PREPARATION, SHOP COAT, COATING APPLICATION & REPAIR AND DOCUMENTATION General
5.1.1 In order to achieve the maximum durability, one or more of following methods of surface preparation shall be followed, depending on condition of steel surface and as instructed by Engineer-in-Charge. Adhesion of the paint film to surface depends largely on the degree of cleanliness of the metal surface. Proper surface preparation contributes more to the success of the paint protective system: a. b. c.
SMELTER DIVISION
Manual or hand tool cleaning Mechanical or power tool cleaning. Blast cleaning.
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5.1.2 Mill scale, rust, rust scale and foreign matter shall be removed fully to ensure that a clean and dry surface is obtained. The minimum acceptable standard in case of manual or hand tool cleaning shall be St.2 or equivalent, in case of mechanical or power tool cleaning it shall be St.3 or equivalent, in case of blast cleaning it shall be Sa2V2 or equivalent as per Swedish Standard SIS-055900-1967 / ISO-8501-11988. Where highly corrosive conditions exist, then blast cleaning shall be Sa3 as per Swedish Standard. Remove all other contaminants, oil, grease etc. by use of an aromatic solvent prior to surface cleaning. 5.1.3 Blast cleaning shall not be performed where dust can contaminate surfaces undergoing such cleaning or during humid weather conditions having humidity exceeding 85%. Irrespective of the method of surface preparation, the first coat of primer must be applied on dry surface. This should be done immediately and in any case within 4 hours of cleaning of surface. However, at times of unfavorable weather conditions, the Engineer-in-Charge shall have the liberty to control the time period, at his sole discretion and / or to insist on re-cleaning, as may be required, before primer application is taken up. In general, during unfavorable weather conditions, blasting and painting shall be avoided as far as practicable. The external surface of R.C.C. chimney to be painted shall be dry and clean. Any loose particle of sand, cement, aggregate etc. shall be removed by scrubbing with soft wire brush if necessary, acid etching with 10-15% HCL solution for about 15 minutes shall be carried out and surface must be thoroughly washed with water to remove acid & loose particles then dry completely before application of paint. 5.2
Procedure of Surface Preparation
5.2.1 Blast Cleaning 5.2.1.1
Air Blast Cleaning The surfaces shall be blast cleaned using one of the abrasives: A1203 particles chilled cast iron or malleable iron and steel at pressure of 7kg/cm2 at appropriate distance and angle depending on nozzle size maintaining constant velocity and pressure. Chilled cast iron, malleable iron and steel shall be in the form of shot or grit of size not greater than 0.055" maximum in case of steel and malleable iron and 0.04" maximum in case of chilled iron. Compressed air shall be free from moisture and oil. The blasting nozzles should be venturi style with tungsten carbide or boron carbide as the materials for liners. Nozzles orifice may vary from 3/16" to 3/4". On completion of blasting operation, the blasted surface shall be clean and free from any scale or rust and must show a grey white metallic lusture. Primer or first coat of paint shall be applied within 4 hours of surface preparation. t Blast cleaning shall not be done outdoors
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in bad weather without adequate protection or when there is dew on the metal, which is to be cleaned. Surface profile shall be uniform to provide good key to the paint adhesion (i.e. 35 to 50/i). If possible vacuum collector shall be installed for collecting the abrasives and recycling. 5.2.1.2
Water Blast cleaning Environmental, health and safety problems associated with abrasive blast cleaning limit the application of Air Blast Cleaning in many installations. In such case water blast cleaning is resorted to. Water Blast Cleaning can be applied with or without abrasive and high pressure water blasting. The water used shall be inhibited with sodium chromate / phosphate. The blast-cleaned surface shall be washed thoroughly with detergents and wiped with solvent and dried with compressed Air. For effective cleaning abrasives are used. The most commonly used pressure for high pressure water blast cleaning for maintenance surface preparation is 3000 to 6000 psi at 35-45 liters/minute water volume and pressures up to 10000 psi and water volume of 45 liters/minute provide maximum cleaning. The water blast cleaned surface shall be comparable to SSPC-SP12/NACE NO.5. The operation shall be carried out as per SSPC guidelines for water blast cleaning. The indicative values for sand injection is:
Air : 300 to 400 Cu.ft/min. Water : 5-10 litres/min. with corrosion inhibitor Sand 200 - 400 lbs/hr. Nozzle : 0.5 |to 1" dia Special equipments for water blast cleaning with abrasives now available shall be use
!
5.2.2 Mechanical or Power tool cleaning
Power tool cleaning shall be done by mechanical striking tools, chipping hammers, grinding wheels or rotating steel wire-brushes. Excessive burnish of surface shall be avoided as it can reduce paint adhesion. On completion of cleaning, the detached rust mill scale etc. shall be removed by clean rags and / or washed by water or steam and thoroughly dried with compressed air jet before application of paint. |
5.2.3 Manual or hand tool cleaning: Manual or hand tool cleaning is used only where safety problems limit the application of other surface preparation procedure and hence does not appear in the specifications of paint systems. Hand tool cleaning normally consists of the following:
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Hand de-scaling and / or hammering Hand scraping Hand wire brushing
Rust, mill scale spatters, old coatings and other foreign matter, shall be removed by hammering, scrapping tools, emery paper cleaning, wire brushing or combination of the above methods. On completion of cleaning, loose material shall be removed from the surface by clean rags and the surface shall be brushed, swept, dedusted and blown off with compressed air / steam to remove all loose matter. Finally the surface may be washed with water and dried for effective cleaning. j i
5.3
Non compatible shop coat primer The compatibility of finishing coat should be confirmed from the paint manufacturer. In the event of use of primer such as zinc Rich epoxy, inorganic zinc silicate etc. as shop coat, the paint system shall depend on condition of shop coat. If shop coat is in satisfactory condition showing no major defects, the shop coat shall not be removed. The touch up primer and finishing coat(s) shall be identified for application by Engineer-in charge.
5.4
Shop coated (coated with primer & finishing coat) equipment should not be repainted unless paint is damaged.
5.5
Shop primed equipment and surfaces will only be 'spot cleaned' in damaged areas by means of power tool brush cleaning and then spot primed before applying one coat of field primer unless otherwise specified. If shop primer is not compatible with field primer then shop-coated primer should be completely removed before application of selected paint system for particular environment.
5.6
For packaged units / equipment, shop primer should be as per the paint system given in this specification. However, manufacturer's standard can be followed after review.
5.7
Coating Procedure and Application : '
j
5.7.1 Surface shall not be coated in rain, wind or in environment where injurious airborne elements exists, when the steel surface temperature is less than 5°F above dew point, when the relative humidity is greater than 85% or when the temperature is below 40°F. 5.7.2 Blast cleaned surface shall be coated with one complete application of primer as soon as practicable but in no case later than 4 hrs. the same day. 5.7.3 To the maximum extent practicable, each coat of material shall be applied as a continuous film uniform thickness free of probes. Any spots or areas missed in application shall be recoated and permitted to dry before the next
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coat is applied. Applied paint should have the desired wet film thickness. 5.7.4 Each coat shall be in proper state of cure or dryness before the application of succeeding coat. Material shall be considered dry for recoating when an additional coat can be applied without the development of any detrimental film irregularities, such al lifting or loss of adhesion of the under coat. Manufacturer instruction shall be followed for inter coat interval. 5.7.5 When the successive coat of the same colour have been specified, alternate coat shall be tinted, when practical, sufficiently to produce enough contrast to indicate complete coverage of the surface. The tinting material shall be compatible with the material and not detrimental to its service life. 5.7.6 Air spray application shall be in accordance with the following: ; a.
The equipment used shall be suitable for the intended purpose, shall be capable of properly atomizing the paint to be applied, and shall be equipped with suitable pressure regulators and gauges. The air caps, nozzles, and needles shall be those recommended by the manufacturer of the equipment for the material being sprayed. The equipment shall be kept in satisfactory condition to permit proper paint application.
b.
Traps or separators shall be provided to remove oil and condensed water from the air. These traps or separators must be of adequate size and must be drained periodically during operations. The air from the spray gun impinging against the surface shall show no condensed water or oil.
c.
Ingredients shall be kept properly mixed in the spray pots or containers during application by continuous mechanical agitation. d. The pressure on the material in the pot and of the air at the gun shall be adjusted for optimum spraying effectiveness. The pressure on the material in the pot shall be adjusted when necessary for changes in elevation of the gun above the pot. The atomizing air pressure at the gun shall be high enough to properly atomize the paint but not so high as to cause excessive fogging of paint, excessive evaporation of solvent, or less by over spray.
e.
Spray equipment shall be kept sufficiently clean so that dirt, dried paint, and other foreign materials are not deposited in the paint film. Any solvents left in the equipment shall be completely removed before applying paint to the surface being painted.
f.
Paint shall be applied in a uniform layer, with overlapping at the edge of the spray pattern. The spray patterns shall be adjusted so that the
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paint is deposited uniformly. During application, the gun shall be held perpendicular to the surface and at a distance, which will ensure that a wet layer of paint is deposited on the surface. The trigger of the gun should be released at the end of each stroke. ; g. h.
All runs and sags shall be brushed out immediately or the paint shall be removed and the surface repainted. Areas inaccessible to the spray gun shall be painted by brush; if not accessible by brush, daubers or sheepskins shall be used.
i. All nameplates, manufacturer's identification tags, machined surfaces, instrument glass, finished flange faces, control valve items and similar items shall be masked to prohibit coating desposition. If these surfaces are coated, the component shall be cleaned and restored to its original condition. j. first
Edges of structural shapes and irregular coated surfaces shall be coated and an extra pass made later.
k. 5.7.7
If spray gun shows choking, immediately de-choking procedure shall be followed.
Airless spray application shall be in accordance with the following procedure: as per steel structure paint Manual Vol. 1 & Vol.2 by SSPC, USA , Air less spray relies on hydraulic pressure rather than air atomization to produce the desired spray. An air compressor or electric motor is used to operate a pump to produce pressures of 1,000 to 6,000 psi. Paint is delivered to the spray gun at this pressure through a single hose within the gun, a single paint stream is divided into separate streams, which are forced through a small 6rifice resulting in atomization of paint without the use of air. This results in more rapid coverage with less over spray. Airless spray usually is faster, cleaner, more economical and easier to use than conventional air spray. Airless spray equipment is mounted on wheels, and paint is aspirated in a hose that sucks paint from any container, including drums. The unit shall have inbuilt agitator that keep the paint uniformly mixed during the spraying. The unit shall consist of inbuilt strainer. Usually very small quantities of thinning are required before spray. Incase of High Build epoxy coatings(two pack). 30:1 pump ratio and 0.020-0.023" tip size will provide a good spray pattern. Ideally fluid hoses should not be less than 3/8" ID and not longer than 50ft to obtain optimum results. In case of gun choking, de-choking steps shall be followed immediately.
5.7.8 Brush application of paint shall be in accordance with the following :
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a.
Brushes shall be of a style and quality that will enable proper application of paint.
b.
Round or oval brushes are most suitable for rivets, bolts, irregular surfaces, and rough or pitted steel. Wide flat brushes are suitable for large flat areas, but they shall not have width over five inches.
c.
Paint shall be applied into all corners.
d.
Any runs or sags shall be brushed out.
e.
There shall be a minimum of brush marks left in the applied paint.
f.
Surfaces not accessible to brushes shall be painted by spray, daubers, or sheepskin.
5.7.9 Manual Application by sling (where 6 O' clock position of pipe is not approachable) A canvas strip (alternatively a tinplate strip) about 450mm wide and 1.5m long is hold under the pipe by two men. Liquid coating is poured on the sling at each side of the pipe. The men holding this sling move it up and down and walk slowly forward while fresh coating is poured on the pipe and they manipulate the sling so that an even coating is obtained all round the bottom. This work shall be done very carefully and by experienced personnel. There shall not be any formation of "Whiskers" and, holes in the coating. The coating film shall be inspected by mirror. 5.7.10 For each coat the painter should know the WFT corresponding to the specified DFT and standardize the paint application technique to achieve the desired WFT. This has to be ensured in the qualification trial. 5.8
Drying of coated Surfaces
5.8.1 No coat shall be applied until the preceding coat has dried. The material shall be considered dry for re-coating when another coat can be applied without the development of any film irregularities such as lifting or loss of adhesion of undercoats. Drying time of the applied coat should not exceed maximum specified for it as a first coat; if it exceeds the paint material has possibly deteriorated or mixing is faulty.
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No paint shall be force dried under conditions, which will cause checking, wrinkling, blistering formation of pores, or detrimentally affect the condition of the paint. 5.8.2 No drier shall be added to paint on the job unless specifically called for in the manufacturer's specification for the paint. 5.8.3 Paint shall be protected from rain, condensation, contamination, snow and freezing until dry to the fullest extent practicable. 5.9 Repair of damaged paint surface 5.9.1 Where paint has been damaged in handling and in transportation, the repair of damaged coating of pre-erection / fabrication shall be as given below. 5.9.2 Repair of damaged inorganic zinc silicate primer after erection / welding : Quickly remove the primer from damaged area by mechanical scraping and emery paper to expose the white metal. Blast cleans the surface if possible. Feather the primer over the intact adjacent surface surrounding the damaged area by emery paper. 5.9.3 Repair of damaged pre-erection and shop priming in the design temperature of -90°C to 500°C. - Surface preparation shall be done as per procedure 5.9.2. - One coat of F-9 shall be applied wherever damaged was observed on ire- erection / pre-fabrication / shop primer of inorganic zinc silicate coating (F-9). F-9 shall not be applied if damaged area is not more than 5x5 cm. 5.10 PAINT APPLICATION 5.10.1 Shop priming / pre-erection priming with F9 or F12 shall be done only on blasted surface. 5.10.2 Shop priming / pre-erection priming with F9 or F12 shall be done only with airless spray. 5.10.3 For large flat surface field painting shall be done by airless spray otherwise brush can be used. 5.11 Documentation A written quality plan with procedure for qualification trials and for the actual work. 2. Daily progress report with details of weather conditions, particular of 1.
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applications, no of coats and type of materials applied, anomalies, progress of work versus programme. 3. Results of measurement of temperatures relative humidity, surface profile, film thickness, holiday detection, adhesion tests with signature of appropriate authority. 4. Particulars of surface preparation and paint application during trials and during the work. 5. Details of non-compliance, rejects and repairs. 6. Type of testing equipments and calibration. 7. Code and batch numbers of paint materials used 6.0
PAINT MATERIALS Paint manufacturers shall furnish all the characteristics of paint materials on printed literature, along with the test certificate for all the specified characteristics given in these specifications. All the paint materials shall be of first quality.
6.1
List of recommended manufacturers The paints shall conform to the specifications given above and the best quality in their products range of the manufacturers listed in Annexure-I.
7.0
PAINT SYSTEMS The paint system should vary with type of environment envisaged in and around the plants. Three types of environment as given below are considered for selection of paint system. The paint system is also given for specific requirements. PRIMERS & FINISH COATS COVERED IN TABLE NOS.: PRIMERS P-2
:
Chlorinated Rubber Zinc Phosphate Primer
P-4
:
Etch Primer/Wash Primer
P-6
:
Epoxy Zinc Phosphate Primer
FINISH COATS/PAINTS i
F-2
:
F-3
:
Chlorinated Rubber Finish Paint
F-6
:
High Build Epoxy finish coating
SMELTER DIVISION
Acrylic - Polyurethane finish paint
'
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F-7
:
High Build Coal Tar epoxy coating
F-8
:
Self priming surface Tolerant High Build Epoxy coating.
F-9
:
Inorganic Zinc Silicate coating.
F-11
:
Heat resistant Synthetic medium based Aluminium paint
F-12
:
Heat resistant Silicone Aluminium paint.
F-14
:
Specially formulated polyamine cured coal for Epox coating.
F-15
:
Epoxy phenolic coating
F-16
:
Epoxy Siloxane Coating : Amercoat 738
Field paint system for carbon steel storage tanks (external) for all environments s. No. 11.1
DESIGN TEMPERATUR E IN *c
SURFACE PREPARATION
PAINT SYSTEM FIELD PRIMER
FINISH PAINT
TOTAL DFT REMARKS IN MICRONS (MIN)
11.2
EXTERNAL SHELL, WIND GIRDERS APPARATUSES, ROOF TOPS OF ALL ABOVE GROUND TANK INCLUDING TOP SIDE OF FLOATING ROOF OF OPEN TANK AS WELL AS COVERED FLOATING ROOF TANK AND ASSOCIATED STRUCTURAL WORKS, ROLLING AND STATIONARY LADDERS, SPIRAL STAIRWAYS, HAND RAILS FOR ALL ENVIRONMENTS FOR CRUDE OIL, LDO, HSD, ATF, KEROSENE, GASOLENE, MOTOR SPIRIT, DM WATER, FIREWATER, RAW WATER, POTABLE WATER, ACIDS, ALKALIES SOLVENTS AND CHEMICALS ETC. -14 TO 80 SSPC-SP-10 285 1 COATOFF-6 @100n 1 COATOFF-9* ©65F-6 should be DFT/COAT + 2 COATS 75(1 DFT/COAT + 1 suitable for OF F-2 ®40(i COAT OF P-6 @40(i occasional water DFT/COAT 2X40=80 DFT/COAT immersion. 65+40=105 81 TO 500 SSPC-SP-10 2 COATS OF F-12 105 1 COAT OF F@20n DFT/COAT 2X20=40 9* @65-75n DFT/COAT EXTERNAL SURFACES OF BOTTOM PLATE (SOIL SIDE) FOR ALL STORAGE TANKS.
11.2.1
-14 TO 80
11.1.1
11.1.2
* Same
SSPC-SP-10
1 COAT OF F9* Q65-75n DFT/COAT
3COATSOFF-7 ®100n DFT/COAT 3X100=300
365
F-7 should be suitable for immersion service of the products given.
as pre-erection / pre-fabrication
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Table 12.0 : S. No. 12.1
Field paint system for carbon steel and alloy steel storage TANKS:(INTERNAL)
DESIGN TEMPERATURE IN-
S URF
PAINT SYSTEM FIELD PRIMER
T O
FINISH PAINT
REMARKS
12.4
INTERNAL SURFACES OF UNDERSIDE OF FLOATING ROOF, INTERNAL SURFACE OF CONE ROOF, BOTTOM PLATE, ROOF STRUCTURE, STRUCTURAL STEEL, LADDERS, SUPPORTS FOR STORING CRUDE OIL, LDO, AND HSD (EXCLUDING WHITE OIL PRODUCTS) -14 TO 80 SSPC-SP-10 3COATSOFF-7 ©100(i 365 F-7 should be 1 COAT OF F-9 DFT/COAT suitable for 665-75(1 3X100=300 Immersion service of DFT/COAT the products given. BARE SHELL OF INSIDE FLOATING ROOF TANKS AND CONE ROOF TANKS FOR PRODUCTS MENTIONED IN 12.1. -14 TO 80 SSPC-SP-10 20 PHOSPHATING 2 COATS © TREATMENT W I T H 10(i PHOSPHATING 2x10=20 CHEMICALS (2 COATS) FLOATING CONE ROOF TANKS FOR PETROLEUM PRODUCTS SUCH AS ATF, GASOLINE, NAPTHA, KEROSENE, MOTOR SPIRIT, INSIDE OF BOTTOM PLATE, UNDERSIDE OF FLOATING ROOF AND SHELL ABOVE MAXIMUM LIQUID LEVEL AND STRUCTURAL STEEL, LADDERS ETC. -14 TO 80 SSPC-SP-10 365 1 COAT OF F-9 3COATSOFF-6 F-6 should be ©65-75(1 DFT/COAT ©100(i DFT/COAT suitable for 3X100=300 Immersion service of petroleum products like ATF, Kerosene, BARE SHELL OF INSIDE OF FLOATING CONE ROOF TANKS FOR PRODUCTS MENTIONED IN 12.3.
12.4.1
-14 TO 80
SSPC-SP-TO 1 COAT OF F-9 ©65-75(1 DFT/COAT
12.7
No over coating Is allowed. Same as per pre-erection primer, if any. INTERNAL PROTECTION OF FIXED ROOF TYPE STORAGE TANKS FOR POTABLE WATER : INSIDE OF SHELL, UNDER SIDE OF ROOF AND ROOF STRUCTURE INSIDE SURFACE, BOTTOM PLATE AND STRUCTURAL STEEL WORKS, LADDERS, WALKWAYS, PLATFORMS ETC. -14 TO 80 SSPC-SP-10 2 COATS OF P-6 2 COATS OF F-6 280 F-6 shall be suitable ©40(1 DFT/COAT ©100(1 DFT/COAT for Immersion service. 2X40=80 2X100=200 D.M. (DEMINERALISED WATER) AND HYDROCHLORIC ACID (HCL) : INTERNAL SHELL, BOTTOM PLATE AND ALL ACCESSORIES -14 TO 60 SSPC-SP-10 EBONITE RUBBER LINING AS PER SMMS SPECIFICATIONS 6-06-204 EG TANKS (INTERNAL SHELL, BOTTOM PLATE ROOF AND ALL ACCESSARIES).
12.7.1
ALL
SSPC-SP-10
12.8
INSIDE PONTOON AND INSIDE OF DOUBLE DECK OF ALL FLOATING ROOFS.
12.8.1
-14 TO 80
SSPC-SP-3
200
12.9
1 COATOFF-8 1 COAT OF F-6 © 100(1 DFT/COAT © 100(1 1x100=100 DFT/COAT INTERNAL SURFACES OF AMINE & SOUR WATER STORAGE TANKS
12.9.1
-14 TO 80
SSPC-SP-10
215-225
12.1.1
12.2 12.2.1
12.3 12.3.1
12.5 12.5.1 12.6 12.6.1
SMELTER DIVISION
NONE
3 COATS VINYL CHLORIDE CO-POLYMER AMERCOAT 23 ©75(i/COAT
1 COAT OF F-9 ©65-75(1 DFT/COAT
2COATSF-15 © 75(i DFT/COAT 2x75=150
65-75
225
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Table 13.0 : Sl.No.
13.1 13.1.1 13.1.1.1
13.1.2 13.1.2.1
13.2 13.2.1 13.3
Coating system for external side of underground carbon steel plant piping and tanks.
DESIGN TEMPERA TURE IN *e
PAINT SYSTEM
SURFACE PREPARA TION
PRIMER
REMARKS
TOTAL OFT IN MICRONS( MIN.)
FINISH PAINT
PIPING (UNDERGROUND)
.. ... _. .
YARD COATING 25 TO 60
SSPC-SP-10
1 COAT OF SYNTHETIC FAST DRYING PRIMER, TYPE-B AS PER AWWAC-203(1991)
4mm THICK COALTAR COATING WRAPPING AS PER AWWA-C-203 IN 2 LAYERS OF EACH 2mm THICKNESS.
4mm
1 COAT OF SYNTHETIC FAST DRYING PRIMER, TYPE-B AS PER AWWAC-203(1991)
2 LAYERS OF COAL TAR BASED TAPE COATING AS PER AWWA-C-203 & AS PER SMMS NALCO SPEC. 6-06-203REV.2
4mm
NONE
65-75
3COATSOFF-7 9100ji DFT/COAT 3X100=300
365
CTE coating shall confirm to 120/5 as par BS:4164
OVER THE DITCH COAIINU 25 TO 60
SSPC-SP-10
CARBON SPUN PIPING (UNDERGROUND) 61 TO 400
SSPC-SP-10
1 COAT OF F-9 96575!i DFT/COAT
UNINSULATED UNDERGROUND STORAGE" TANKS:
13.3.1
-40 TO 80
SSPC-SP-10
1 COAT OF F-9 9 6575 \L DFT/COAT
13.3.2
-90 TO -41 81 TO 400*C
SSPC-SP-10
1 COAT OF F-9 96575n DFT/COAT OR 1 COAT OF AMERCOAT 738 9250ii DFT/COAT
NONE
6
NONE 5
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Table 14.0 : Painting under insulation for insulated (hot, cold & safety) carbon steel, low alloy steel, low temperature carbon steel & stainless steel piping, storage tanks and equipments in all environment. S. No.
TEMPERATURE IN Deg C
PAINT SYSTEM
PREPAR ATION
FINISH PAINT
PRIMER
14.1
INSULATED CARBON STEEL, LOW ALLOY STEEL AND LTCS PIPING AND EQUIPMENT
14.1.1
-45 TO 125
14.1.2
SSPC-SP-10 R E P A I R O P E R A T I N G TEMPERATURE OF PREFABRICATE 45 TO 125"C BUT PRIMER F-9 ®65-75n DESIGN DFT TEMPERATURE 126-400"C INSULATED STAINLESS STEEL INCLUDING ALLOY-20 PIPING
14.2
SSPC-SP-10 REPAIR OF PREFABRICATION PRIMER F-9 985-75*1 DFT
315 2COATSOFF-14 9125(i DFT/COAT= 2x125=250 OR 3 COATS OF F15=3x80=240 105-115 3 COATS OF F-12 920(i DFT/COAT 3X20=60
14.2.1
BELOW 0*C TO ALL MINUS TEMPERATURE
ALUMINIUM SHEETING WITH ALUMINIUM FOIL AND "CHLORIDE FREE MINERAL SEALANT CONTAINING BARIUM CHROMATE" SHALL BE APPLIED
14.2.2
OTO 120
14.2.3
121 TO 500
NONE SSPC-SP10 (1525n SURFAC E SSPC-SP-10 NONE
14.2.4
501 TO 1000
SSPC-SP-10 NONE
14.2.5
CYCLIC SERVICE -196 TO 480 EXCEPTING 45 TO 120
SSPC-SP-10 NONE
14.3
NO PAINTING IS REQUIRED FOR INSULATED MONEL, INCOLOY AND NICKEL LINES
SMELTER DIVISION
2COATSOFF-14 9125(i DFT/COAT=2x 125=250 OR 3 COATS OF F3COATSOFF-12 920(i DFT/COAT 3X20=60 1 COAT OF AMERCOAT 738 @150n DFT/COAT 1 COAT OF AMERCOAT 738 @ 150ti DFT/COAT
REMARKS
TOTAL DFT IN MICRONS( MIN.)
250
60
150
150
For other temperature ranges no painting is required under insulation.
If the pi p in g & equipments are already erected then surface shall be prepared by cleaning with emery paper and wash / flush with chloride free DM water followed by wiping with organic solvent No pre-erection primer to be applied. Only Amercoat 738 from Ameron is available for this temperature range
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17.0
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STORAGE
17.1 All paints and painting materials shall be stored only in rooms to be arranged by contractor and approved by Engineer-in-charge for the purpose. All necessary precautions shall be taken to prevent fire. The storage building shall preferably be separate from adjacent building. A signboard bearing the words "PAINT STORAGE NO NAKED LIGHT- HIGHLY INFLAMMABLE" shall be clearly displayed outside. 18.0 COLOUR CODE FOR PIPING
18.1 SR.
For identification of pipelines, the colour code as per Table 18.1 shall be used. Paint materials for color-coding shall be as specified in this standard in clause6.0. Colour coding scheme for pipes, equipment, machinery & structures: DESCRIPTION
GROUND
FBRST COLOUR
SECOND
COLOUR
BAND
COLOUR BAND
DRINKING WATER
Sea Green
French Blue
Signal Red
DE-MINERALISED WATER
-do-
Gulf Red
-
COOLING WATER BOILER FEED WATER
-do-do-
French Blue Gulf Red
-
-do-
Light Brown
Signal Red
-do-
Dark Grey
-
WASH WATER PROCESS WATER
-do-
-do-
Canary Yellow Oxide Red
-
FIREWATER
Fire Red
Crimson Red
-
SEA WATER
Sea Green
White
-
STEAM VERY HIGH PRESSURE STEAM (VHP)
Aluminium to IS2339 Signal Red
-
HIGH PRESSURE STEAM (SH)
-do-
French Blue
-
MEDIUM PRESSURE STEAM (SM)
-do-
Gulf Red
-
LOW PRESSURE STEAM (SL)
-do-
Canary Yellow
-
DILUTION STEAM / PURGE STEAM
-do-
Grey
Canary Yellow
COMPRESSED AIR PLANT AIR INSTRUMENT AIR
Sky Blue -do-do-
Signal Red Silver Grey French Blue
-
NITROGEN
Canary Yellow
Black
-
OXYGEN
-do-
White
-
C02
-do-
Light Grey
NO.
18.1. ALL KINDS
CONDENSATE QUENCH WATER
18.1.2
18.1.3
,
;
•
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DESCRIPTION
GROUND COLOUR
FIRST COLOUR BAND
SECOND COLOUR BAND
FUEL GAS AND SOUR GAS
Canary Yellow
Grey
Dark Violet
CHARGE GAS
-do-
Signal Red
French Blue
RESIDUE GAS, LPG ACETYLENE SWEET GAS
-do-do-do-
Oxide Red Service Brown Grey
White -
SULFURIC ACID
Dark Violet
Brilliant Green
Light Orange
NITRIC ACID
-do-
French Blue
-do-
HYDROCHLORIC ACID
-do-
Signal Red
-do-
ACETIC ACID
-do-
Silver Grey
-do-
CAUSTIC
Smoke grey
Light orange
-
CHLORINE
Canary Yellow
Dark violet
-do-
HYDRO CARBONS NAPTHAS
Dark Admiralty Grey Brilliant Green
Black
PROPYLENE PROPYLENE C.G.(LIQ)
-do-do-
-do-do-
Smoke Grey Gulf Red
ETHYLENE GLYCOL
-do-
-Do-
-
ETHYLENE DICHLORIDE
-do-
Gulf Red
-
BENZENE
-do-
Canary Yellow
-
BUTADIENE
-do-
Black
ETHANE
Dark Admiralty Grey Light Grey
French Blue
PROPYLENE(LIQ)
-do-
Signal Red
Black
ETHYLENE(LIQ)
-do-
Light Grey
Black
TAR/ PITCH
-do-
Signal Red
Brilliant Green
AROMATIC GASOLINE
-do-
Brilliant Green
Canary Yellow
METHANOL(LIQ)
-do-
White
Gulf Red
PYROLYSIS GASOLINE
-do-
Brilliant Green
Black
MDCED C4(LIQ)
-do-
Signal Red
Light Brown
LPG(LIQ) KEROSENE
-doLight Brown
Brilliant Green -do-
Dark Violet -
DIESEL OIL(WHITE)/ HTF
-do-
-do-
-
DIESEL ODKBLACK)
-do-
-
18.1.4 GASES
18.1.5 ACIDS AND CHEMICALS
18.1.6
i
18.2
The colour code scheme is intended for identification of the individual group of the pipeline. The system of colour coding consists of a ground colour and colour bands superimposed on it.
18.3
Ground Colours as given in Table-18.1 shall be applied throughout the entire length for uninsulated pipes, on the metal cladding & on surfaces covered by Clause 2.2.2, ground colour coating of minimum 2m length or of adequate length not to be mistaken as colour band shall be applied at places requiring colour bands. Colour band(s) shall be applied at the following location. a.
SMELTER DIVISION
At battery limit points
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b. c.
Intersection points & change of direction points in piping ways. Other points, such as midway of each piping way, near valves, junction joints of service appliances, walls, on either side of pipe culverts.
d.
For long stretch/yard piping at 50M intervals.
e.
At start and terminating points.
18.4 Identification Sign 18.4.1
Flow direction shall be indicated by an arrow in the location stated in Para a,b,c & d and as directed by Engineer-in-Charge.
18.4.2
Colours of arrows shall be black or white and in contrast to the colour on which they are superimposed.
18.4.3
Product names shall be marked at pump inlet, outlet and battery limit in a suitable size as approved by Engineer-in-Charge.
18.4.4
Size of arrow shall be either of those given in 18.5
18.5
Colour Bands
18.5.1 table:
As a rule minimum width of colour band shall conform to the following
Nominal Pipe Size
Width: L(mm)
3" NB and below above 3" NB upto 6" NB above 8" NB upto 12" OD above 12" OD
25mm 50mm 75mm 100mm
Note: For insulated pipes, nominal pipe size means the outside diameter of insulation. Nominal pipe size figures are to be in inches. 18.5.2 and the
Colour band(s) shall be arranged in the sequence shown in Table 18.1 sequence follows the direction of flow. The relative proportional width of the first colour band to the subsequent bands shall be 4:1, minimum width of any band shall be as per Clause 18.5.1. ;
18.6
SMELTER DIVISION
Whenever it is required by the Engineer-in-Charge to indicate that a pipeline carries a hazardous material, a hazard marking of diagonal
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strips of black and golden yellow as per IS.2379 shall be painted on the ground colour. 19.0
IDENTIFICATION OF VESSELS, PIPING ETC.
19.1
Equipment number shall be stenciled in black or white on each vessel, column, equipment & machinery (insulated or uninsulated) after painting. Line number in black or white shall be stenciled on all the pipe lines of more than one location as directed by Engineer-in-Charge^ Size of letters printed shall be as below: Column & Vessels Pump, compressor and other machinery Piping -
150mm(high) - 50mm ( high) 40-150mm
19.2 Identification of storage tanks: The storage tanks shall’ be marked as detailed in the drawing. 20.0
PAINTING FOR CIVIL DEFENCE REQUIREMENTS
20.1
Following items shall be painted for camouflaging if required by the client. a. b. c. d.
All columns All tanks in offsites. Large Vessels Spheres
20.2
Two coats of selected finishing paint as per defence requirement shall be applied in a particular pattern as per 20.3 and as per the instructions of Engineer-in-Charge.
20.3
Method of camouflaging
20.3.1
'
Disruptive painting for camouflaging shall be done in three colours in the ratio of 5:3:2 (all matt finish). Dark Green
Light Green
Dark Medium Brown
5:
3:
2
20.3.2
The patches should be asymmetrical and irregular.
20.3.3
The patches should be inclined at 30 Degree to 60 Degree to the
horizontal. 20.3.4
SMELTER DIVISION
The patches should be continuous where two surfaces meet at an angle.
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20.3.5
The patches should not coincide with corners.
20.3.6 20.3.7
Slits and holes shall be painted in dark shades. Width of patches should be 1 to 2 metres
21.0
INSPECTION AND TESTING
21.1
All painting materials including primers and thinners brought to site by contractor for application shall be procured directly from manufactures as per specifications and shall be accompanied by manufacturer's test certificates. Paint formulations without certificates are not acceptable.
21.2
Engineer-in-Charge at his discretion, may call for tests for paint formulations. Contractor shall arrange to have such tests performed including batch wise test of wet paints for physical & chemical analysis. AH costs there shall be borne by the contractor.
21.3
The painting work shall be subject to inspection by Engineer-in-Charge at all times. In particular, following stage wise inspection will be performed and contractor shall offer the work for inspection and approval of every stage before proceeding with the next stage. The record of inspection shall be maintained in the registers. Stages of inspection are as follows: a. b. c.
Surface preparation Primer application Each coat of paint
In addition to above, record should include type of shop primer already applied on equipment e.g. Red oxide zinc chromate or zinc chromate or Red lead primer etc. Any defect noticed during the various stages of inspection shall be rectified by the contractor to the entire satisfaction of Engineer-in-Charge before proceeding further. Irrespective of the inspection, repair and approval at intermediate stages of work, contractor shall be responsible for making good any defects found during final inspection/guarantee period/defect liability period as defined in general condition of contract. Dry film thickness (DFT) shall be checked and recorded after application of each coat and extra coat of paint should be applied to make-up the DFT specified without any extra cost to owner, the extra cost should have prior approval of Engineer-in-Charge. 21.4 Primer Application After surface preparation, the primer should be applied to cover the crevices, corners, sharp edges etc. in the presence of inspector nominated by Engineerin-Charge.
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21.5
The shades of successive coats should be slightly different in colour in order to ensure application of individual coats, the thickness of each coat and complete coverage should be checked as per provision of this specification. This should be approved by Engineer-in-Charge before application of successive coats.
21.6
The contractor shall provide standard thickness measurement instrument with appropriate range(s) for measuring. Dry film thickness of each coat, surface profile guage for checking of surface profile in case of blast cleaning. Holiday detectors and pinhole detector and positector whenever required for checking in case of immersion conditions.
21.7
Prior to application of paints on surfaces of chimneys, the thickness of the individual coat shall be checked by application of each coat of same paint on M.S.test panel. The thickness of paint on test panel shall be determined by using gauge such as 'Elkometer'. The thickness of each coat shall be checked as per provision of this specification. This shall be approved by Engineer-inCharge before application of paints on surface of chimney.
21.8
At the discretion of Engineer-in-Charge, the paint manufacturer must provide the expert technical service at site as and when required. This service should be free of cost and without any obligation to the owner, as it would be in the interest of the manufacturer to ensure that both surface preparation and application are carried out as per their recommendations.
21.9
Final inspection shall include measurement of paint dry film thickness, Adhesion, Holiday detection check of finish and workmanship. The thickness should be measured at as many points/locations as decided by Engineer-inCharge and shall be within +10% of the dry film thickness, specified in the specifications.
21.10 The contractor shall arrange for spot checking of paint materials for Sp. gr., flow time(ford cup) and spreading rate. 22.0
GUARANTEE
22.1
The contractor shall guarantee that the chemical and physical properties of paint materials used are in accordance with the specifications contained herein/to be provided during execution of work.
22.2
The contractor shall produce test reports from manufacturer regarding the quality of the particular batch of paint supplied. The Engineer-in-Charge shall have the right to test wet samples of paint at random, for quality of same, as stipulated in Clause 11 above. Batch test reports of the manufacturer's for each batch of paints supplied shall be made available by the contractor.
23.0
QUALIFCATION CRITERIA OF PAINTING CONTRACTOR
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Painting contractor who is awarded any job for NALCO, Projects under this standard must have necessary equipments, machinery, tools and tackles for surface preparation, paint application and inspection. The contractor must have qualified, trained and experienced surface preparator, paint applicator, inspector and supervisors. The contractor supervisor, inspector, surface preparator and paint applicator must be conversant with the standards referred in this specification. The contractor’s capacity, capability and competency requirements for the job shall be quantified in the tender document and shall be assessed by an NALCO team before awarding any job.
24.0 PROCEDURE FOR APPROVAL OF NEW COATING MATERIALS AND MANUFACTURERS Following procedure is recommended to be followed for approval of new manufacturers. 24.1
The manufacturer should arrange testing of the inorganic zinc silicate coating materials as per the list of tests given in para 24.5 below from one of the reputed Government laboratories.
24.2
Samples of coating materials should be submitted to the Govt, laboratory in sealed containers with batch no. and test certificate on regular format of manufacturer s testing laboratory. The sampling shall be certified and sealed by a certifying agency.
24.3
AH test panels should be prepared by Govt, testing agency coloured photographs of test panels should be taken before and after the test and should be enclosed along with test report. Samp of batch no. and manufacturer's test certificate should be enclosed along with the report. Test report must contain details of observation and rusting if any, as per the testing code. Suggested Government laboratories are: RRL .Hyderabad HBTI, Kanpur DMSRDE, Kanpur IIT, Mumbai BIS Laboratories. UDCT, Mumbai RITES, Calcutta PDIL
24.4 Manufacturers should intimate The Company, details of sample submitted for testing, name of Govt, testing agency, date, contact personnel of the Govt, testing agency. At the end of the test the manufacturer should submit the test reports to the company for approval. The manufacturer(s) shall be qualified based on the results of these tests and other assessment and the Company's decision in this regard shall be final and binding on the manufacturer.
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24.5
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Tests required for evaluation of acceptance of coating materials for offshore application. Test
ASTM Test Method
Density
D 1475
Dipping properties
D 823
Film Characteristics Drying time Flexibility Hardness
D 1640 D 1737/D 522 D3363
Adhesion D2197 Abrasion resistance D 968/D 1044 DFT/Coat AS PER SSPC GUIDELINES Storage Stability D 1849 Resistance to Humidity for 2000 hrs. D 2247 Salt Spray for 2000 hrs. B 117 Accelerated Weathering D822 ! j % Zn in DFT G53 Coating systems for panel test shall be decided after discussion with NALCO.
Annexure-I LIST OF RECOMMENDED MANUFACTURERS Indian Vendors 1.0 2.0 3.0 4.0 5.0
Asian paints(I) Ltd. Berger Paints Ltd. Goodlass Nerolac paints Ltd. Jenson and Nicholson paints Ltd. & Jenson & Nicholson Ltd. Shalimar paints Ltd,
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NATIONAL ALUMINIUM COMPANY LIMITED
NOTES:
1.
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2.
ALL LETTERS.BLOCKS AND BORDER SHALL BE OF RAISED POLISHED FACE.
3.
BACK GROUND SHALL BE BLACK.
4.
NAME PLATE SHALL BE TACK-WELDED TO THE BRACKET. WHERE.NOT POSSIBLE IT MAY BE RIVETTED
5.
NAME PLATE SHALL BE OF STAINLESS STEEL OF 2mm THICK
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NOTE:
SMELTER DIVISION
1. 2. 3. 4.
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED. ALL LETTERS.BLOCKS AND BORDER SHALL BE OF RAISED POLISHED FACE BACK GROUND SHALL BE BLACK. NAME PLATE SHALL BE TACK-WELDED TO THE BRACKET. WHERE NOT POSSIBLE IT MAY BE R!VESED
5.
NAME PLATE SHALL BE OF STAINLESS STEEL OF 2mm THICK.
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NOTES 1.
SMELTER DIVISION
ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE STATED. DOCUMENT TITLE
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2.
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BRACKET MATERIAL SHALL BE SAME AS SHELL MATERIAL
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NOTES: 1. 2. 3. 4. 5.
6. 7.
SMELTER DIVISION
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED. AT THE TIME OF WELDING EAR PLATE '16' WITH ITEM T INSURE THAT ANNULAR GAP BETWEEN ITEM 1 AND 2 IS UNIFORM THROUGHOUT THE PERIPHERY. ALL HOLES SHALL BE RIMMED AFTER DRILLING. CONTACT FACE OF INSERT RINGS SHALL BE MACHINED TO HAVE GAS TIGHT SEAL FOR HYDROCARBON SERVICE USE TYPE-1 AND FOR GENERAL SERVICE USE TYPE-2. THIS STANDARD IS APPLICABLE ONLY FOR NON-PRESSURE TANKS. DIMENSIONS SHOWN IN BRACKETS ARE FOR 250N6 GAUGE HATCH.
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NOTES 1.
^
REFERENCE LINES SHALL BE LIGHTLY PUNCH-MARKED INSIDE AND OUTSIDE AROUND THE CIRCUMFERENCE OF THE SHELL PLATE ON THE TANGENT UNES OF THE VESSEL
2. a) OUT OF ROUNDNESS (OVAUTY) SHALL BE AS PER APPLICABLE CODE. b) OUTSIDE CIRCUMFERENCE OF SHELL SHALL BE WITHIN THE FOLLOWING LIMITS. + 10 mm FOR NOMINAL DIAMETER 1200 mm AND UNDER. ± 12 mm FOR NOMINAL DIAMETER 1201 mm THROUGH 2400 mm. + 20 mm FOR NOMINAL DIAMETER ABOVE 2400 mm. c) FOLLOWING TOLERANCES ON DIAMETER SHALL APPLY THROUGHOUT ITS LENGTH FOR VESSELS WrTH TRAYS AND / OR PACKING. (FOR CARTRIDGE TYPE TRAY REFER SPECIAL NOTE-E).
VESSEL NOM. DIA. 2000 2001 4001 ~AB0VE
I
TOLERANCE ON NOM. DIA.
mm AND UNDER ______________________________ + 0.5S _____________________ mm TO 4000 mm __________ GREATER OF + 10 mm OR ± 0.35K ~ mm TO 8000 mm ____________ GREATER OF * 14 mm OR ± 0.25% ____________ 8000 mm j TO BE SPECIFIED ON VESSEL DRAWING.
3. TOLERANCE FOR LENGTH ± 5 mm / 3000 mm, MAXIMUM 15 mm. 4. OUTSIDE SURFACE OF CYLINDER MAY BE OUT OF ALIGNMENT / STRA1GHTNESS NOT MORE THAN 6 mm / 6000 mm STRAIGHT LENGHT, BUT NOT MORE THAN 20 mm FOR ANY LENGTH. 5. TOLERANCE FOR CENTRE TO CENTRE DISTANCE BETWEEN ANY PAIR OF INSTRUMENT CONNECTIONS TO BE AS FOLLOWS:D1STANCE BETWEEN NOZZLES : + 1 mm ORIENTATION : ± 1 mm NOZZLE FACE INCLINATION : ± 1/4 ° 6. ELEVATIONS FROM REFERENCE PLANE MAY VARY AS FOLLOWS:MANHOLE: ± 12 mm. NOZZLE ± 6 mm, INTERNAL SUPPORTS: ± 3 mm, EXCEPT THAT LOCATIONS OF MANHOLES AND NOZZLES NEAR THE TRAY SHALL NOT VARY MORE THAN ± 3 mm FROM THE TRAY. 7. PROJECTION OF FLANGE FACE FROM SHELL CENTRAL LINE / TANGENT UNE MAY VARY ± 5 mm FOR NOZZLES AND ± 12 mm FOR MANHOLES. 8. 9. 10. 11. 12.
CIRCUMFERENTIAL AND RADIAL DEVIATION OF NOZZLES, MANHOLES AND SUPPORTS FROM THE TRUE POSITION SHALL NOT VARY MORE THAN ± 3 mm. BOLT HOLE ORIENTATION OF NOZZLES MAY VARY ± 2 mm AT BOLT CIRCLE. VERTICAL AND HORIZONTAL DEFLECTION OF NOZZLE FLANGE FACES FROM PLANES NORMAL TO NOZZLE CENTRE UNES OR PARALLEL TO VESSEL CENTRE UNE SHALL NOT BE MORE THAN ± 1 /2 . ° ALL TOLERANCES OF TRAY SUPPORTS TO BE AS PER TRAY SPECIFICATIONS / DRAWING. THE BASE RING BOLT CIRCLE DIAMETER MAY VARY ± 5 mm. FOR ANY DIAMETER MEASURED AT POINTS 90* APART, DISTANCE BETWEEN TWO CONSECUTIVE HOLES MAY VARY BY ± 5 mm.
13. a)
DEVIATION OF SUPPORTBASE FROM HORIZONTAL IS AS F0LL0W5:FOR VESSEL DIA. 1500 mm AND UNDER 3 mm FOR VESSEL DIA. OVER 1500 mm TO 2000 mm 5 mm FOR VESSEL DIA. OVER 2000 mm TO 4000 mm 6 mm FOR VESSEL DIA. OVER 4000 mm TO 5000 mm 8 mm FOR VESSEL DIA. OVER 5000 mm 10 mm b) DEVIATION OF SUPPORT BASE FOR BRACKET TYPE SUPPORT / SADDLE SUPPORT FROM HORIZONTAL IS ± 1? 14. DISTANCE BETWEEN CL TO CL OF SUPPORTS: AND BOLT HOLES IN SUPPORTS FOR HORIZONTAL VESSELS MAY VARY + 3 mm. 15. DISTANCE BETWEEN CENTRE UNE OF.-HORIZONTAL VESSEL AND BOTTOM OF SUPPORT MAY VARY ± ;i mm. 16. a) TOLERANCE FOR CENTRE TO CENTRE DISTANCE BETWEEN ANY PART OF EXTERNAL STRUCTURAL ATTACHMENT SHALL NOT VARY MORE THAN ± 3 mm. b) TOLERANCE FOR DISTANCE FROM REFERENCE PLANE TO BASE OF VERTICAL SUPPORTS AND CENTRE UNE OF SADDLE SUPPORT MAY VARY ± 6 mm.
SPECIAL NOTES A.
CUMULATIVE TOLERANCES ON CONSECUTIVE DIMENSIONS SHALL BE UMITED BY OVERALL DIMENSIONAL TOLERANCE. ALL TOLERANCES ARE FROM REFERENCE PLANE UNLESS OTHERWISE INDICATED.
B.
INTERFERENCE BETWEEN INTERNAL AND EXTERNAL PARTS OR ANY RESTRICTION TO THE INTENDED FUNCTION OF ANY PART SHALL BE KEPT IN VIEW WHERE TOLERANCES ARE CUMULATIVE.
C. SPECIFIC TOLERANCES FOR ANY PART SHOWN ON NALCO DRAWING SHALL BE GIVEN PREFERENCE TO THOSE GIVEN IN THIS STANDARD. D. UNUSUALLY LARGE OR COMPLEX VESSELS MAY BE EXECUTED WHEN THE TOLERANCES AS SHOWN ARE UNREASONABLE IN SUCH INSTANCES. FABRICATOR'S TOLERANCES & UMITS MUST BE SUBMITTED FOR APPROVAL. E.
VESSEL UPTO AND INCLUDING 750 mm NOMINAL DIAMETER SHALL HAVE CARTRIDGE TYPE TRAY. FOLLOWING TOLERANCES ON DIAMETER SHALL APPLY THROUGHOUT ITS LENGTH.________________________________________
VESSEL NOMINAL DIAMETER
|
TOLERANCE
500 mm AND UNDER _______________________________VESSEL LP. 501 mm TO 750 mm ___________________ _________VESSEL I.D.
SMELTER DIVISION
t j, g£ __________ * s mm _________
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NOTES 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED. 2. THIS STD. IS APPLICABLE FOR VESSEL DIAMETER UPTO ANO INCLUDING 2000mm, MAXIMUM SHELL THICKNESS OF 20mm AND MAXIMUM LENGTH (T.L. TO T.L.) OF 3000mm VESSELS' BEYOND ABOVE RANGE REQUIRE SPECIAL CONSIDERATION. 3. FOR CALCULATION. FOLLOWINGS PARAMETER?. HAVE BEEN CONSIDERED. a) WIND PRESSURE ../•"" 200 Kg/m2 SHAPE FACTOR " 0.7 BASIC SEISMIC CO-EFFICENT (a„) 0.08 SOIL FOUNDATION SYSTEM FACTOR ( p ) 1.5 IMPORTANCE FACTOR (I) 2.0 b) EMPTY WEIGHT WITH WIND LOADING OR HYDROSTATIC WEIGHT WITH SEISMIC LOAOING. 4. HEIGHT AMD NUMBER OF LEG SUPPORTS AND SIZE OF ANCHOR BOLTS SHALL BE AS PER ENGINEERING Drawing. 5. MINIMUM BOLT SIZE SHALL BE M 20. 5. MAXIMUM INSULATION THICKNESS CONSIDERED !S 150 mm. 7. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN. 6. ALL FILLET WELDS SHALL BE 6 mm MINIMUM. 9. MATERIALS SHALL BE AS PER ENGINEERING DRAWING. 9. EARTHING LUG SHALL 8E AS PER STANDARD 7-12-026
LEG SUPPORT SIZES VESSEL NO 0/D(mm) LEGS
LEG SIZE MAX. VESSEL LENGTH
(T.L. TO T.L.) UP TO
*N0 INCLUDING 3.0 M
BASE PLATE SIZE (mm)
X (mm)
MAXIMUM ALLOWABLE LOAD OF VESSEL (Kg.)
L = 1.5 M
L = 2.0 M
500
3
ISA 100x100x8
ISA 100x100x10
ISA 110x110x15
170x170x16 THK.
40
1500
800
4
ISA 100x100x10
ISA 130x130x8
ISA 130x130x12
200x200x16 THK.
45
3150
SMELTER DIVISION
L = 2.5 M
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1000
4
ISA 100x100x12
ISA 130x130x10
ISA 150x150x12
230x230x16 THK.
45
4600
1250
4
ISA 110x110x15
ISA 150x150x10
ISA 150x150x12
230x230x16 THK.
45
6750
1600
4
ISA 130x130x15
ISA 150x150x15
ISA 150x150x18
230x230x16 THK.
60
9500
1750
4
ISA 150x150x12
ISA 150x150x18
ISA 200x200x12
300x300x16 THK.
60
12700
2000
4
ISA 150x150x18
ISA 200x200x12
ISA 200x200x15
300x300x20 THK.
75
16400
NOTES FOR A VESSEL WITH MAXIMUM SUPPORT LEG HEIGHT OF 1500mm, FOLLOWING ALTERNATIVE LEG SIZES MAY BE USED :, o) ISA 60x60x8 WITH HYDROSTATIC WEIGHT UPTO 500 Kg. b) ISA 80x80x8 WITH HYDROSTATIC WEIGHT 501 Kg. TO 1000 Kg,
SMELTER DIVISION
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1801 - 2000
650
500
400
550
25
14
350
50
1601 - 1800
600
450
350
500
25
14
300
50
1401 - 1600
550
400
300
450
25
14
250
50
1201 - 1400
500
350
250
450
25
12
200
25
1001 - 1200
450
320
220
400
20
12
180
25
801 - 1000
450
280
200
400
20
12
150
25
A
B
C
E
F
G
H
J
VESSEL OUTSIDE DIA.
M
SEE ENGINEERING DRAWING M30 (MINIMUM)
OVERALL PAGE
5EE ENGINEERING DRAWING 60 (MINIMUM)
PROJECT TITLE
ADDITIONAL LIQUID PITCH HANDLING SYSTEM
ANCHOR BOLT DtA.
550
60
540
55
540
50
470
40
450
30
450
25
'X' UAXMUU
MAXIMUM
v Essa WEIGHT (TONNE)
NOTES: 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED, 2. NUMBER OF BRACKETS SHALL BE FOUR PER VESSEL 3. PAD THICKNESS SHALL BE AS PER ENGINEERING DRAWING. 4. FOR VESSELS UPTO 800 mm DIA. REFER ENGINEERING DRAWING. 5. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN. 6. DISTANCE 'X' IS TO BE FINALIZED CONSIDERING INSULATION THICKNESS, BOLT SIZE- REQUIREMENT AND SHALL BE KEPT MINIMUM.. 7. EARTHING LUG SHALL BE AS PER STANDARD 7-12-026
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FLANGE RATING
CLASS 300
CLASS 600
CLASS 900
G
400
298
450
d
R
<*1
L
28
35
55
36
42
318
28
35
55
36
42
500
34B
28
35
55
36
42
600
406
28
35
55
36
42
400
324
28
35
55
36
42
450
355
28
35
55
36
42
500
336
30
35
55
36
42
600
458
30
35
55
36
42
400
342
32
40
55
41
47
450
372
32
40
60
41
47
500
406
36
40
60
41
47
600
470
36
40
75
41
47
400
352
32
40
60
41
47
450
394
32
40
65
41
47
500
428
40
40
70
41
47
600
520
40
40
90
41
47
-tj
CLASS 150
NOMINAL BORE
NOTES 1. ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED. 2. WELD HINGE TABS AFTER TIGHTENING THE COVER WITH GASKET IN PLACE AND MAINTAIN A LOOSE FTT OF HINGE BAR IN HINGE TABS. 3. BCD OF JACK SCREWS IS TO BE SUITABLY CHANGED IF MANHOLE STUDS INTERFERE With JACK SCREWS. 4. SQUARE RODS IF USED. THE EDGES SHALL BE ROUNDED OFF. 5. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
6. 6. ALL FILLET WELDS SHALL BE 6mm MINIMUM. 7. TELLTALE HOLE SHALL NOT BE PLUGED AND SHALL BE FILLED WITH HARD GREASE ONLY 8. THE MATERIAL OF COMPONENTS SHALL GENERALLY BE IS: 2062 UNLESS OTHERWISE SPECIFIED ON ENGINEERING DRAWING. FOR LOW TEMPERATURE SERVICES AND SERVICES ABOVE 425"C THE HINGE TABS AND HANDLE SHALL BE OF SAME MATERIAL AS THAT OF SHEL
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NOTES 1.
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED.
2.
VARIATION IN SPACING BETWEEN LADDER RUNGS IS PERMITTED HOWEVER THE SPACING OF RUNGS SHALL BE EQUAL.
3.
SQUARE RODS MAY BE USED FOR HANDGRIP / LADOER RUNGS. IF FABRICATED FROM PLATE THE EDGES ARE TO BE ROUNDED OFF.
4.
MATERIAL SHALL BE AS PER ENGINEERING DRAWING.
5. 6.
ALL FILLET WELDS SHALL BE 6 mm MINIMUM.
SMELTER DIVISION
ORIENTATION OF LADDER RUNGS SHALL BE SAME AS OF MANHOLE.
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NOMINAL PIPE SIZE
OUTSIDE DIAMETER
BELOW 3"
STANDARD
L
OF PAD)
(WIDTH SHELL WELD EFF.=0.85
SHELL WELD EFF.-1.0
PROJECTION (A) SEE NOTE-4 CLASS 150
CLASS 300
CLASS 600 CLASS 900
-
_
150
150
150
150
r
88.9
40
45
200
200
200
200
4"
114.3
50
60
200
200
200
200
6"
168.3
70
85
200
200
200
250
a"
219.0
95
110
200
200
250
250
10"
273.0
115
135
200
200
250
300
12"
323.8
135
160
200
200
250
300
14"
355.6
150
175
250
250
250
300
16"
406.4
170
200
250
250
250
300
iar
457.2
195
225
250
300
300
350
20"
508.0
215
250
250
300
300
24"
609.6
255
300
250
300
k-53^'
.
,
350 400
NOTES 1. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE STATED. 2. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN 3. CHECK REINFORCEMENT REQUIREMENT FOR ALL EXTERNAL PIPING LOADING ALSO. 4. NOZZLE PROJECTIONS ARE BASED ON INSULATION THICKNESS EQUAL TO 75mm. FOR INSULATION THICKNESS GREATER THAN 75mm, THE NOZZLE PROJECTION IS A + [INSULATION THICKNESS (mm)-75] 5. PROJECTION 'A’ FOR SELF-REINFORCED NOZZLE SHALL BE BASED ON DESIGN OF REINFORCEMENT. 6. EXTEND PAD LOCALLY FOR MANHOLE DAVIT SUPPORT, IF REQUIRED. 7. TELLTALE HOLE SHALL NOT BE PLUGGED AND SHALL BE FILLED WITH HARD GREASE ONLY.
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NOTES 1. 2.
3. 4.
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ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED. DIMENSION ‘E’ IS TO BE DETERMINED BY THE SHAPE OF HEAD IN CONJUNCTION WITH DIMENSION 'K'. DETAIL, DIMENSIONS AND NOTES GIVEN IN ENGINEERING DRAWING TAKE PRECEDENCE OVER THOS SHOWN HERE. FOR THIN WALLED EQUIPMENTS. DESIGNER SHALL ANALYSE THE STIFFENESS OF SHELL AT THE LIFTING LUG LOCATION.
5. IF PADS ARE USED ON STAINLESS STEEL EQUIPMENTS THE SIZE OF FILLET WELD BETWEEN SHELL AND STAINLESS STEEL PAD SHALL BE ANALYSED. 6.
MATERIAL SHALL BE COMPATIBLE WITH HEAD MATERIAL.
7. FOR INTERMIDIATE ERECTION WEIGHT. NEXT HIGHER SIZE OF LIFTING LUG SHALL BE USED. 8. LIFTING LUG SHALL BE MACHINED TO COVER OFFSET BETWEEN OUTER DIAMETERS OF SHELL AND HEAD.
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NOTES: 1. ALL DIMENSIONS ARE IN mm. 2. FOR MATERIAL SPECIFICATION REFER ENGINEERING DRAWING. 3. ‘P’ SHALL BE EQUAL TO 175mm FOR VESSELS UPTO 3000mm DIAMETER AND 300mm FOR VESSELS ABOVE 3000mm DIAMETER. 4. DETAILS. DIMENSIONS ANO NOTES ON ENGINEERING DRAWING SHALL TAKE PRECEDENCE OVER THOSE SHOWN HEREIN. 5. CLIPS SHALL CLEAR WELD SEAMS AND INSULATION RINGS SHALL BE SUITABLY NOTCHED INCASE OF INTERFERENCE WITH NOZZLES/ATTACHMENTS. 6. ONLY T-CLEATS WITH ASBESTOS SHEET AND G.I. BOLTINGS, ANGLE RING ALONG WITH TACK WELDED BOLTS. INSULATION SUPPORTS CLEATS WELDED TO EQUIPMENT. LOOSE RINGS AND M l 2 NUTS SHALL BE SUPPLIED BY EQUIPMENT FABRICATOR. 7. FOR COLD INSULATED VESSELS CLEATS ON DISHED ENDS ARE NOT REQUIRED. 8. FOR COLD INSULATED VESSELS CLEATS ON SHELL ARE TO BE PROVIDED IF COLD INSULATION THICKNESS IS MORE THAN 60MM.
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NOTES: ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE STATED. ALL EQUIPMENTS ARE TO 8E PROVIDED WITH MINIMUM 2 EARTHING LUGS. EARTHING LUGS SHALL BE LOCATED DIAMETRICALLY OPPOSITE ON NORTH-SOUTH CENTER LINE ON SKIRT SUPPORTED EQUIPMENTS, ON ANY TWO LEGS OF 3 LEG SUPPORTED VERTICAL VESSEL 4. ON DIAMETRICALLY OPPOSITE LEGS OF 4 LEG SUPPORTED VERTICAL VESSEL AND ON EACH SADDLE OF HORIZOTAL VESSEL. TWO (2) EATHING LUGS ARE TO BE LOCATED ON EACH SADDLE OF HORIZONTAL VESSEL OF LENGTH GREATER THAN 20 METERS. 5. DO NOT WELD EARTHING LUG ON PRESSURE PART. IN CASE OF CONFLICT ENGINEERING DRAWING SHALL GOVERN.
1. 2. 3.
SMELTER DIVISION
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STANDARD SPECIFICATION FOR HOT INSULATION OF VESSELS, PIPING AND EQUIPMENT
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CONTENTS 1. 2. 3. 4. 5. 6.
SMELTER DIVISION
GENERAL SCOPE DESIGN BASIS MATERIALS APPLICATION INSULATION FINISH
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1.0 1.1
GENERAL SCOPE
1.1.1
This specification covers design and material requirements for above ground, external insulation of piping and equipment operating between ambient temperature and 550°C for the purpose of heat conservation, process stabilisation, temperature maintenance, personnel protection and fire protection. Wherever necessary this specification indicates the basis for selecting a criterion.
1.1.2
This specification is suitable for use in outdoor service with normal process plant atmospheres. Alternative designs and materials would be specified by NALCO if necessary for corrosive atmosphere or potential leaks and spills of chemicals.
1.1.3
This specification does not cover insulation for boiler or fired heaters and associated air heaters, economizers, flue ducting and air ducting.
1.1.4
Piping, equipment, storage tanks and vessels requiring insulation shall normally be specified on the following project documents.
1 2 3 4 5
Process and Instrument Diagrams (P&lDs)and Line Lists Piping General Arrangement Drawings 1 Isometrics Instrument Piping Details and Schedules NALCO Vessel, Exchanger,Storage Tank and sphere documents & Insulation Schedules supplier's General Arrangement Drawings for equipment items in package plant.
2.0
DESIGN BASIS
2.1
CRITERIA
2.1.1
Heat Conservation Insulation is designed for economic thicknesses and to limit cold surface temperatures below 65°C with 200C ambient temperature in still air conditions.
2.1.2
Internally refractory lined piping and equipment and any other items for which heat loss is essential shall not be insulated. (See para 2.3.6.4)
2.1.3
Insulation is not desired for piping and equipment for which heat loss is desired - excepting for personnel protection or to avoid thermal stress problems.
2.1.4
Insulation is required for any of the following purposes, as indicated in PIDs and line lists: • Heat conservation • Process stabilisation to assist process control • Stream tracing
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• • • • • • •
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Electric tracing Hot water or solvent tracing (liquid) Hot Oil tracing Steam jacketting Hot water or liquid jacket-ing Hot Oil Jacketing Fire hazard protection to prevent fast boil off of liquid Personnel protection: Applicable where exposed surface temperatures exceeds 65*0 in normal or short-term operating conditions. Over internally insulated piping and equipment, provide 5[open mesh metal guards and for surfaces pnich are not internally insulated,provide insulation on that part of surfaces with which operating and maintenance personnel may come in contact while performing routine duties. The intent of PilD's, line classification lists, Engineering drawings etc. which designate insulation for personnel protection is to call attention only to the eligibility of such service. The actual extent of insulation shall be determined by Field Construction Personnel and/or operating personnel using the following criteria: Exposed surfaces operating above 65°C and located within 600 mm horizontally or 2100 mm vertically of a normal access, walkway or work area.
2.1.5
Instruments and associated piping subject to operating flow and/or temperature conditions prevailing in the connected piping or equipment shall be insulated to the same requirements as that of piping or equipment.
2.2
Extent of Insulation on Piping Systems:
2.2.1
Insulated piping systems shall have straight pipe, bends, tees and pipe fittings completely insulated.
2.2.2
All valves and flanged joints shall be completely insulated only in steam, condensate service, hot oil lines and in lines which are trace heated or jacket-ed to maintain temperatures.
2.2.3
For bucket and float type traps the inlet piping and trap shall be insulated.
2.2.4
Insulation on inlet piping to thermostatic and thermodynamic steam traps shall terminate at approximately 500 mm before the trap.
2.2.5
Steam trap outlet piping other than closed condensate recovery system shall not be insulated except for personnel protection reasons.
2.2.6
Instrumentation to be insulated, such as level gages, level controllers, level switches, dp cells, shall have their fluid containing sections and the associated piping completely insulated, including pipes, valves and fittings.
2.2.7
Insulation shall not be applied to the following, unless otherwise specified. • Piping which becomes hot intermittently, such as relief valves, vents, steamout and snuffing steam systems, flare and blowdown systems.
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• Supports for piping, excluding pipe hangers to the extent covered by insulation. • Steam Traps (except as noted in paragraph 2.2.3 • Valves, including control valves and flanges in process piping systems (except as noted in 2.2.2 and 2.2.8). However, personnel protection insulation for these items shall be applied, as required. • Pipe Union fittings. • Thermowell bosses and pressure tappings. • Expansion joints, hinged joints and hose assemblies • Sight flow indicators. 2.2.8
Insulation shall be designed to provide an absolute minimum clearance of 25 mm between the outside surface of any insulation finishing material and adjecant surfaces.
2.2.9
Where insulated horizontal piping is supported on steel shoes, the height of the shoe shall be such that the underside of the insulation finishing material is clear of the supporting structures upon which the shoe rests by 25mm minimum.
2.3
Extent of Insulation on Equipment:
2.3.1
Support skirts of insulated vertical vessel greater than 1200 mm diameter shall be insulated both internally and externally for a minimum distance of 600 mm below the bottom tangent line. The insulation shall terminate not less than 300mm-above tie support concrete orsteel work.
2.3.2
Support skirts of insulated vertical vessels of 1200 mm and less shall be insulated externally only, as described in para 2.3.1 above.
2.3.3
Bottom heads of insulated vertical vessels enclosed by a support skirt shall be insulated without finishing material and shall be insulated only when the vessel outside diameter is greater than 1200 mm.
2.3.4
Turbines and steam ends of reciprocating pump shall be insulated for heat conservation.
2.3.5
Liquid ends of pumps shall be insulated when heat traced or jacket-ed.
2.3.6
Insulation shall not be applied to the following unless otherwise specified. • Pumps with operating temperature below 200°C unless pumped fluid has a pour point above minimum design ambient temperature. • Fans, compressors, blowers or other rotating or reciprocating equipment. • Liquid ends of pumps except as noted in the paragraph 2.3.5 above. • Internally insulated or refractory lined equipment unless specially designed for metal temperature control. • Heads of vessels enclosed by support skirts with vessel diameters 1200 mm and less.
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• Internal surfaces of insulated vessel support skirts with vessel diameter 1200 mm or less. • Turbine casings to be insulated shall exclude shaft seal caps, shaft bearing housings, throttle valves, governors and supports.Zz • Exchanger channel and covers; shell and channel flanges, t Exp. Joints. • Nozzles, manholes and handholes and flanges of equipment, • Surfaces of coolers and condensers. • Namplates of all equipment items. • Thermowell bosses and pressure tappings. 3.0
MATERIALS
3.1
GENERAL
3.1.1
All material shall be of high quality and good appearance. This specifications covers five materials - Rockwool, Glass Wool, Calcium Silicate, Polyisocyanurate and cellularglass.
3.1.2
Insulation materials shall be of low chloride content, chemically inert, nonsulphurous, rot proof, vermin proof, impervious to hot water and steam, non-injurious to health and non-corrosive to steel and aluminium (pven if soaked in water at ambient temperatures for extended periods).
3.1.3
The use of insulation or finishing materials containing ASBESTOS in any form is not permitted.
3.1.4
Insulation and jacketing material backed with paper or other flamable material is not acceptable.
3.1.5
Many common flammable liquids such as oil, butanol, diethanolamine and hexanol will react and start fires when they leak into inorganic absorbent insulations. Such absorbent insulations can store large quantities of combustible liquids should a leak occur. This could be a decisive factor when specifying and evaluating alternative materials.
3.1.6
Insulation materials have been classified into two categories - water absorbing and non-water absorbing. Non-water absorbing insulants like polyisocynurate and cellular glass are recommended for services upto 125°C. Water absorbing insulants like fibrous insul&flts and calcium silicate can be used for all temperatures except for electrically traced pipe-But for low temperature (i.e. upto 125°C) services a suitable moisture barrier shall be used sinre the substrata is at too low a temperature to evaporate moisture, rain or hose water absorbed
3.2 3.2.1
Insulation Material Fibrous Material (Rock § Glass Wool)
3.2.1.1 Shall be a preformed insulation and shall be of. long fibred rock or glass material processed from a molten state into fibrous form
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bonded with a binder and suitable for the temperature range from ambient to 550°C. acceptable.
intended operational Slagwool is not
3.2.1.2 Unless otherwise specified herein, insulation material shall strictly conform to all the requirements of quality standards listed below : • IS:9842:Latest issue : Preformed pipe insulation • IS:8183: Latest issue : Metal-mesh covered bonded mineral Fibre blanket & blanket type pipe insulation for piping & equipment faced on one side with 20mm galvanised No. 22 SWG. Wire Mesh, Stitched through with 22 SWG galvanised lacing wire : Mattress for Lined covers shall be faced on one side with 20mm galvanised 22SWG wiremesh stiched through with 22SW3 galvanised lacing wire. • IS:8183 : Latest issue: Mineral fibre block & board thermal insulation • Insulation shall conform to following requirement and shall be tested and test certificates on representative samples furnished to NALCO as per IS: 8183/IS: 9842 (latest issue) for conformance to each of the following requirements. • Density : 140 to 150 kg/m (Density shall be within this range and density test. shall be as per IS:5388/IS 3144 latest Issue) • Shot Content(IS:3144) Shot shall not be more than 5mm in any dimensions; shot content, when sieved as fo11ows and shall not exceed as per below: IS Sieve(IS:460) 500 micron 250 micron • • •
by
Moisture content and absorption: Not more than 2% Incombustibility(IS:3144) : Incombustible, Loss in weight not more than 5% Thermal Conductivity( IS:3346) Minimum Temperature °C 50 100 150 200 250 300 Mean Temp= (Hot Temp)/2
Sulpher Content (IS : 3144)
SMELTER DIVISION
Shot Content, Percent Mass (Max.) 5 15
Thermal Conductivity mW/ cm°C. 0. 13 0.52 0.02 0.68 0.80 0.90 Face Temp+Cold Face
Not more than 0.6 percent.
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Linear Shrinkage (IS : 3144)
Not more than 2 percent unen subjected to so;iking conditions of soaking heat at the stated maximum temperature of use (550°C) for 24 hours.
Heat Resistance (IS : 3144)
When heated to max. temp. (550T), sample shall maintain its general form and shall not suffer visible deformation of the fibrous structure Compressive Strength (Average) 120 Kg/m2 minimum at 10% deformation Recovery after compress ion After compression to 751 of the original thickness, recovery shall not (IS:8183-Appcndix'A' IS: 9842- be less than 90% of original thickness . Appendix 'A') Alkalinity (IS: 8183 Appendix 'B'/ pH of the solution of the material shall be between 7.0 and 10 .0 IS:9842 Appendix 'B') Chloride Content (IS;3144)
Not to exceed 20 ppm
Dimension
Pipe Section Hollow cylinder, split lengthwise on one or both sides of the cylindrical axis. Thickness : 25,40,50,60 $ 75mm Tolerance in Length : ±3mm Tolerance in Thickness : ±3mm When installed on the pipe of the specified size, sections shall fit snugly and-shall have tight longitudinal and circumferential joint. Blanket Unless otherwise specifically required, standard width shall be 600 to 1200 mm standard length 1500 to 2400mm Thickness : 25,30,40,50,60 5 75mm Tolerance on thickness Positive : 3 mm Negative : -3 mm Block and Boards (IS : 8183: Lengths : 1000 to 1400 mm Widths : 500 to 1000 mm Tolerance : Width and Length : — 3mm, Thickness: ± 3mm.
3.2.2 Rigid Material (Calcium Silicate, Polyisocynurato and Cellular Glass)
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3.2.2.1 Calcium Silicate : Calcium Silicate block and pipe thermal insuluirion shall be composed principally of hydrous calcium silicate reinforced with mineral fiber except slag. It shall be asbestos free. It is suitable for all temperatures. Insulation shall conform to following requirements and shall be tested and test certificates on representative samples furnished to NALCO as per IS : 8154 (latest issue) for conformance to each of the following requirements : Bulk Density 200 to 350 kg/m3 .. To be tested as per IS : 5688. Compressive Strength(for Flatsurfaces only. This test is waived for curved sections) Flexural Strength
Reduction in thickness shall not exceed 10Z when tested per IS:5688* dry under load of 415 kN/m2 and wet (after 18 hrs immersion in water) under a load of 170 kN/m2. *Eventhough CI.6.3.4 of IS:5688 indicates 5Z deformation,test should be conducted for 10Z deformation. Average min.shall be 240 kN/m2 when tested per IS:5688 .
Heat Resistance
When tested per IS : 5724, under conditions of soaking heat for 24 hrs at 650°C. Max. Linear shrinkage : 2Z Max. Loss in weight : 15% Compressive Strength : Reduction in thickness under a load of 345 kN/m2 : 10Z max. When tested as per IS:3346, shall be Mean Temp.°C Thermal Conductivity Max.mW/cm deg. 100 0.65 150 0.75 200 0.80 Not to exceed 7.5Z by mass, when tested per Annex. A. IS : 8154 Not to exceed 20 PPM when tested as per IS:3144 For stainless steels, special quality, with inhibitors, with less than 10 PPM.
Thermal Conductivity
Moisture content Chloride content
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Alkalinity
pH of the solution of the material shall be between 7.0 and 10.0 when tested for Appendix B, IS: 8154.
Dimensions
Flat Blocks: Shall be free from warp. All mating faces shall be' plane and edges shall be square to the surfaces and to one another. Length : 500, 600 or 900 mm. Width : 150, 300 or 600 mm. Thickness* 25, 30, 40, 50, 60, & 75mm Bevelled Lags Length: 500 to 900 mm Major Width: 150 mm Thickness: 25,30,40,50,60 & 75mm. Curved Segments(Radius & bevelled lags) Length: 500 to 1000 mm Thickness:20,25,30,40,50,60 & 75mm. For curved surface having external radius greater than 110 mm. Pipe Sections Hollow cylindrical shapes slit in half lengthwise (in a plane including the cylindrical axis) or as curved segments. Upto 14" pipe size, only hollow cylindrical shapes slit in half lengthwise shall be used. Length: 500 to 1000 mm Diameter: To fit standard size of pipe. Thickness:20,25,30,40,50,60 or 75mm
Dimensional Tolerance Length Width Thickness
Flat Block,Bevelled Pipe Sections & Curved Segments ±3 mm ±3 mm ±3 mm ±3 mm ±3 mm
3.2.2.2 Polyisocyanurate : Rigid Polyisocyanurate foam block, pipe and fitting insulation shall be manufactured with polyester or polyether resins,
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flammability retarding agents, special catalysts and a fluorocarbon blowing agent. This can be used upto a temperature of 125°C. Insulation shall conform to following requirements and shall be tested and test certificates on representative samples furnished to NALCO Site-in-charge for conformance to each of the following requirements: • Selection of samples for testing shall be as per ASTM C390 OR BS:2972 (Frequency of sampling clause IV). Unless otherwise stated, the test specimens shall be conditioned without external stress at 23±1°C and 50±2 percent relative humidity for a minimum of 24 hours before testing. • Density shall be 40 to 64 kg/m3 and shall be tested as per ASTM C303 for Block-type and C302 for pipe covering. Thermal Conductivity Mean Temperature °C 10 24 38
Thermal/Conductivity mW/cm deg.C 0.238 0.245 0.252
value
• Thermal conductivity test shall be as per IS:3346 or ASTM C177. Tests shall be run on samples dried at 102°C - 120°C for constant mass as per ASTM C165. Specimen thickness shall be per IS.-3346 or 25 mm per ASTM C177. • Compressive strength (Min.) after drying at 102° to 120°C for constant mass as per ASTM C165, at 10% deformation or at yield point, whichever occurs first, shall be 205 KPa. Test shall be as per IS:11239 part X. Water vapour permeability, metric perm-cm shall be 4.2. Test shall be a"s per ASTM E 96. • Insulation shall be self-extinguishing type, and satisfy the requirements for maximum extent of burn (less than 25 mm), when tested as per BS:5608 (Horizontal burning characteristics -max. extent of burn ) • Flexural strength (min.) applicable to preformed pipe coverings only shall be 275 KPa. Test as per ASTM C446. Humid aging, (max. allowable value after aging at 60°C-90 to 100% relative humidity) max. percent change in linear dimensions shall be 4. This limit applies to each of the three foam directions. Test shall be as per ASTM D2126. Every 24 hours for 7 days the specimens shall be removed, measured within 60 seconds, allowed to remain in room conditions for 1 hour and remeasured. Measurement at each time interval shall be recorded. The greatest value obtained shall be the value used to determine acceptability. Closed cell content, min#fpercent 85. Test as per BS:4370 Part II (Test for closed cell content) Dimensional stability after heating: Test method as per IS:11239 Part II.
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The max. dimensional change at different temperatures shall be.. 100°C±2°C (24 hr) - 2Z 125°C±2°C (24 hr) - 2Z Insulation shall conform to following requirements and test certificates on representative samples shall be furnished to NALCO as per ASTM C552 for conformance to each of the following requirements : Density 110 to 150 kg/m3 Test as per ASTM C303 except that no drying will be necessary. Determine the no. of specimens as per ASTM C390. Thermal conductivity (average max.) Mean Temp. °C W/ra'k 10 0.058 24 0.060 38 0.062 93 0.013 149 0.086 Test thermal conductivity as per ASTM C240, C 177 and C 518. Test at least 3 specimens. Compressive Strength 517 kPa (Average, min). Test per Method ASTM C240 and Recommended Practice ASTM C 165. Test at least four specimens. Standard size and dimensions BlockLength upto 2400 mm Width upto 1200 mm Tolerance : On length ±6mm On width ±3mm Thickness ±1.6mm Pipe insulation Length 750 to 1000mm Inside dimeter:To suit standard steel pipe. Shall be supplied as cylindrical shape slit in half lengthwise or as curved segments cut from blocks or moulded segments cut from blocks or moulded to shape. Upto 14" size, only pipe sections slit in half lengthwise shall be used. Dimensional: Length ± 6 mm Tolerance : Thickness ± 2.6 mm Thickness :20,25,30,40,50,60 and 75 mm 3.2.2.3
SMELTER DIVISION
Cellular Glass : Cellular Glass foamed and fused into unicellular form can be used upto a temperature of 425°C. But in view of high thermal
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conductivity, its use is limited in this specification to 125°C only as it has been included essentially for its non-water • flexural strength average min, 414 kPa. Test per method ASTM C240 and clause 3.4 of ASTM C203. Determine the method of test specimens as per method ASTM C 390. •
Water absorption, volume X(average max.) 0.5. Test as per method ASTM C240. Test at least 3 specimens.
•
Water vapour transmission(average max.) metric perm-cm or grains/24 h.m2 mm Hg.cm of thickness at 26.7°C : 0.0084. Test as per ASTM E96. Test at least two specimens.
•
Dimensions Flat Blocks : Shall be rectangular sections and shall be true to form and dimension, the corners square and the sides parallel. Size and thickness shall be as follows : Width (mm) 300 450
•
3.2.3
Length (mm) 450 600
Pipe Sections: Shall be supplied as hollow cylindrical shapes split in half lengthwise (in a plane including the cylindrical axis) or as curved segments. Upto 14" size,only pipe sections split in half lengthwise shall be used. The insulation shall be supplied in sections of segments in lengths of 450 mm or 600 mm to fit standard sizes of pipe. Insulation for pipes upto 6" nom. size shall be furnished in 600 mm length, and for pipe above
Pipe
Length
±1.6mm
±3mm
Width
±1.6mm
Thickness
±1.6mm
±3mm
General: Periodical checks for density, thickness, shape and size as per above requirements shall be repeated at site, as per norms and frequency decided at site as per the directions of NALCO Site-in-Charge. Special attention is required for fibrous material as its installed thickness could be reduced due to compaction affecting performance. All the codes mentioned shall be the latest issues. NALCO shall have right to inspect any or all the
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tests conducted on insulation material by manufacturer at his shop or any laboratory. 3.3
Weather Protection Jacket:
3.3.1 Aluminium jacketting shall be used as weather protection over insulation unless otherwise specified and shall be ASTM B209 alloy 3003 H16 or IS:737 designation 31000 (Old NS3) condition H3 for flat sheets and H4 for corrugated sheets. Cladding shall be coated on the side in contact with the insulation with a bitumen anti-corrosive paint.
3.3.1.1
Fibrous Material (Rock & Glass Wool) :
For shells of vertical storage: Tanks & Vessels ) corrugated
0.71mm(22SWG)
For tanks Roofs
: 1.22mm(18SWG)Flat
For horton Spheres &Horizontall vessels shell and heads;vertical vessel heads.
0.71mm(22SWG)Flat
For removable covers
1.22mm( I8SWG)Flat
For all piping,other than grade piping' in Offsite.
0.71mm(22SWG)Flat
For grade piping in ) galvanised Offsites
0.56mm(24SWG)
3.4
)
steel,per IS:277 Class I
Ancilliary Materials
3.4.1 Aluminium Foil to protect Stainless Steel Surfaces Shall be 0.19 mm (36 SWG) thick per ASTM B209 Alloy 3003 H16 or IS:737 designation 31000 (Old NS3) condition H3 3.4.2 Securement Bands/Wires 3.4.2.1
3.4.2.2
If material is Aluminium, then specification shall be ASTM B209 Alloy 3003 H16 or IS: 737 designation 31000 (Old NS3) condition H3; If Stainless Steel, it shall be 18/8. For securing Aluminium foil on Stainless steel surfaces: Band, 24 SWG thick x 20 mm wide, Aluminium.
3.4.2.3
SMELTER DIVISION
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On Piping Brand, 24 SWG thick x 12 (min) wide, Aluminium. On Equipments Band, 24 SWG Thick x 20 wide, Aluminium. On Vertical Storage Tanks Band, galvanised steel, 40 mm wide x 3mm thk., galvanising per IS: 277 class2. Horton Sphere Band, Stainless Steel, 25mm wide x 0.8 mm (min.) thk.
3.4.2.4
For Securing Rigid Insulation
On Piping upto 16" 0D Wire, annealed galvanised steel, 16 SWG, galvanising per class 2 (heavy coatinp of zinc, nominal 600 g/m2) per IS: 277. On Piping 18" OP and Larger Brand, galvanised steel,20 wide X 24 SWG thick,galvanising per above(same as for piping upto 16"OD) On Vertical & Horizontal Vessels Band, galvanized steel, 20 wide x 24 SWG thick, galvanising per above(same as for piping to 16" OD)
3.4.2.5
For Securing cladding on insulation (both fibrous and Rigid For Piping Band, Aluminium 12mm (min) wide x 24 SWG thick. On Equipment Band, Aluminium, 20 mm wide x 24 SWG Thick. On Vertical Storage Tanks Band, Stainless Steel, 25mm wide x 24 SWG thick. On Spheres Band, Stainless Steel, 25 mm wide x 24 SWG thick.
3.4.3
Rivets required for metal jacket 5ecur€lttettfc shall be the expanding Aluminium "POP" blind eye type, 9.5mm long x 5mm diameter.
3.4.4
Screws required for metal jacket securement shall be cadimium plated steel self tapping type A No.8 dia x 12mm long to BS 4176 complete with neoprene washers under the head.
3.4.5
'S' and 'J' clips - Formed from 25mm wide stainless steel banding
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3.4.6
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To ensure perfect water proofing, all the cladding joints shall be packed with sealing materials which may either be in the form of a elastomeric sealing compound or fibre based bituminous felt strips.
4.0 APPLICATION 4.1 General 4.1.1 The application methods, given in this Standard are general in nature. The Contractor is responsible for applying an insulating system that will give a satisfactory operational performance and the requirements given herein shall be regarded as the acceptable minimum. The Contractor shall carryout the work in accordance with the best practices of insulation .application with the minimum of waste and debris and the final job shall have a neat, efficient and workanlike appearance. 4.1.2 All hydrostatic tests on piping and equipment, including steam tracing systems, shall be carried out before insulating material is applied.The insulation Contractor shall only insulate those sections of the plant that has been specifically released for such work by the engineer-in-charge. If insulation must be installed before pressure test, then all welds and flanged joints in the pipe shall be left uncovered till successful completion of pressure test. Then insulation shall be completed. 4.1.3 Surfaces to be insulated shall be thoroughly cleaned, dried and made free from loose scale, oil or grease. It shall be the Contractor's responsibility to remove loosely adhering scale and dirt before applying insulation. 4.1.4 Corrosion Prevention 4.1.4.1 Carbon steel and low alloy piping and equipment with normal operating temperatures of 125°C and below shall be protected against corrosion by painting with a 20 microns (min) dry film thickness of heat resistant aluminium paint suitable for the above temperature. While for equipments (vessels, exchangers, Tanks and spheres), this coating shall be provided by equipment fabricator, for piping, it shall be provided by insulation contractor. 4.1.4.2 Insulation cement shall not be used on stainless steel piping or equipment. 4.1.4.3 All insulated austenetic stainless steel piping and equipment insulated with calcium ©ilicate, Rock or Glass Wool shall he protected against chloride attack as follows : For operating temperatures upto 450*C, the surfaces shall be wrapped with 0.19 mm thick aluminium foil with 50 mm overlap at longitudinal and circumferential joints before application of insulation. All joints of the aluminium foil shall have barium chromate primer interposed. Aluminium foil shall be firmly secured on the stainless
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steel surfaces by Aluminium bands at a pitch of 500 *im. Care shall be taken while applying aluminium foil to ensure that the foil is not punctured at any place during wrapping and clamping with aluminium bands. For Operating temperature above 450°C,the stainless steel surfaces shall be painted with two coats of heat resistant silicon aluminium paint as follows: Type Composit ion
Single Silicon resin based with Aluminium flakes as pigment
Dry Film Thickness
20 microns/coat (minimum)
Other requirements
It should be suitable to withstand temperatures upto 600°C; when the paint becomes dry the paintedsurfaces shall show no discontinuity.
4.1.5 The insulation contractor shall not carryout any welding or drilling on plant equipment and piping. 4.1.6 Insulation shall be finished, beveled and weather-proofed at all terminal points where it is required to remove bolts etc. without damage to the insulation. 4.1.7 Equipment name plates shall remain visible after insulation has been applied by bevelling back the insulating material and carefully sealing the exposed edges to prevent ingress of moisture. 4.1.8 All projections, such as lifting lugs, trunnions and stiffeners of insulation on piping and equipment (i.e. vacuum rings) shall be insulated the same thickness as specified for the equipment item or pipeline. 4.1.9 Thermowell bosses, pressure tappings and weephole nipples shall not be insulated in but left accessible. 4.1.10 Double layer insulation shall be required when the insulation thickness is greater than 75mm. Insulation installed in two or more layers shall be staggered joint construction and each layer shall be secured in place and details of securement shall be the same for each layer. 4.1.11 wet or Damaged Insulation shall not be used under any Circumstances Insulation material to be applied shall not be over bare ground to avoid water absorption. Installed material awaiting its protective cover shall be adequately protected from damage, rain and contamination and shall be covered with cladding at a minimum loss of time. 4.1.12 A minimum clearance of 25mm between outside surface of any insulation finish and adjacent equipment, pipe or structural members shall be maintained
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4.1.13 Insulation supports shall not project out of the insulation outer surface and shall be given sufficient coverage of insulating material to avoid hot spots on the metallic cover at support positions. 4.2 Piping 4.2.1 Material 4.2.1.1
Fibrous Material (Rock or Glasswool) Can be used for all piping other than electrical traced pipes upto 125°C. Can be used for all temperatures. Shall be in preformed pipe section in 2-halves for sizes upto which manufactured and at least for all pipes with outside diameter over insulation of 500mm. In bigger sizes, multi-segments are preferable if manufactured, otherwise, blankets are acceptable. Pieces of insulation with crushed and damaged ends shall not be used.
4.2.1.2
Calcium Silicate • Can be used for all piping other than electrical traced pipes upto 125°C. • Can be used for all temperatures. • Pieces of insulation with crushed and damaged ends shall not be used. • Pipe sections bored/machined out of blocks shall not be used as skineffect is lost.
4.2.1.3
Polyisocyanurate/Cellular Glas • Can be used for all piping including electrically traced piping for service temperatures below 125°C (with electrical and steam tracing the maximum metal temperature reached by tracer in order to conduct the requisite heat into the pipe shall be the deciding factor). • In-situ foaming may be allowed by engineer-in-charge after discussions with client and head-office
4.2.2 Corrosion Protection before applying Insulation: (All insulation materials): • For operating temp, upto 125°C, on carbon and Alloy Steel Piping, provide painting per 4.1.4.1. • For tustcmttic stainless steel piping, provide aluminium barrier, as per Clause 4.1.4.3. 4.2.3 APPLICATION 4.2.3.1
HORIZONTAL PIPE
4.2.3.1.1 Insulation material shall be applied to fit'snugly against the contours and shaped only where necessary to achieve this requirement. The insulation shall be carried out with the least number of material pieces as possible and all unavoidable gaps, cavities, and voids suitably filled with compatible loose fill material
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4.2.3.1.2 Pipe Section/Moulded Blocks/Segments • End joints of adjacent blocks shall be sta- ggered one half of the length of the block. Included angle between segments shall notbe less than 30° for both single and double layer insulation. • Further minimum arc length of segments should meet following staggering requirements. • When double layer is applied, both longitudinal and circumferential joints shall be staggered. The arc between the longitudinal seam lines of the inside and outside layers of insulation shall have an angle of over 15° or the longitudinal joints staggered at least by one layer thickness, whichever is more stringent. Circumferential seams of the inside and out* side layers shall be at least 100 mm apart. 4.2.3.1.3 Mattress (Fibrous insulation-Rock or Glasswool): Shall be applied over the surface with joints tightly butted and laced together with 1 mm dia galvanised lacing wire. 4.2.3.1.4 Insulation Securement (All insulation materials) • Each layer of insulation shall be secured firmly in place with at least 3 loops of binding wire/ band, one loop to be placed not more than 75 from each end and at least? one loop to be equally spaced between end loops,for each section. Binding wire shall be drawn about the insulation with ends tightly twisted together, bent under & pressed into the surface of insulation. Bands or wires in no case be spaced more than 200 nun apart. For calcium Silicate,all joints shall be sealed with insulating cement of same composition as the moulded block. • For Cellular glass and polyisocyanurate,joints shall be sealed with suitable compatible material. • Each layer of insulation shall be secured by the same method as above. 4.2.3.1.5 Frame work for supporting cladding: Fibrous Insulation(See Fig. 3 and 4) • This is not necessary for rigid materials. This is required only for horizontal pipe runs provided with fibrous insulation, in blanket forms; vertical piping provided with fibrous materials need not be provided with this. Piping provided with fibrous resin bonded pipe sections also need not be provided with this framework. • Spacer rings shall be fabricated out of 25x3 M.S. Flats. The outside diameter of these rings shal be equivalent to the outside diameter of the insulation. Spacer rings shall be rivetted to 'Z' shaped stays fabricated from the same sized M.S. Flats. These rings shall be suitably painted corrosion protection. Stays shall be provided at intervals of not more than 300 along the circumference of the insulation, subject to a minimum of 3 stays. Spacer rings shall be provided at every approx. 900.To minimise direct heat conduction through the stays, a packing of 2 sheets of 3 thick asbestos mill board shall be provided at the joints of the stays and pipes. Joints between M.S. Spacer Ring and stays shall be rivetted by 6 dia M.S. Rivets with 2 Sheets of 3 thick asbestos mill board interposed.
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4.2.3.2
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Vertical Pipe (All insulation materials) (See Fig.5) • Insulation on vertical or near vertical piping (i.e. greater than 45° angle from horizontal) shall be supported by bolted on metal collars. Metal collars shall be of 6 thick M.S. or Alloy Steel bar (to suit piping material) • Outside diameter of collar shall be around 12 less than O.D. of insulation. Where multi-layer insulation is used, support collar shall be extended to provide for each layer Support positions shall be at no greater distance apart than the following : Pipe Operating Temp. Upto 400°C 400 to 500°C 500 to 550°C
4.2.3.3
Support Spacing 4500mm 3500mm 2500mm
Expansion Joints (Both vertical and horizontal Piping.. All insulation Materials) (See Fig.5) • Expansion joint shall be provided at regular intervals as below: Temp. °C. Upto 200 200 to 300 300 to 350 350 to 400 400 to 550
Spacing(M) Not required 10 8 6 5
• Expansion joint shall be formed bv a 25mm space between the pipe insulation sections and the space shall be filled by compressed mineral rock fibres. Expansion 'joints in each layer shall be offset at least 150 from each other in case of multilayer insulation. Expansion joint for first layer for vertical pipe shall preferably be just below insulation support collars. 4.2.3.4
Elbows and Bends (All insulation materials): (See Fig. 6 and Fig. 7): Each mitred section shall be secured with minimum 2 wires/bands. For bends/elbows of nom. pipe size 6" & below, due to lack of space, for all insulation materials, insulation shall be secured by spirally wound 16SWG galvanised steel wire for hard materials & 10 SWG galvanised steel wire for soft materials. Insulation joints of block material shall be suitably sealed with adhesive for isocyanurate/ callular glass and by insulating cement for calcium silicate. Fittings below 50mm nom. dia, if insulated of calcium silicate, shall be insulated with insulating cement build up in 6mm layers to the thickness of Insulation of the adjacent piping. Each, layer of insulation cement shall be reinforced with 25mm No. 20 SWG wire netting.
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4.2.3.5
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Tee (All Insulation materials) [See Fig. 8] • Preformed pipe sections or segments shall .be carefully cut and shaped around 'Tee' junctions and the insulation material of the tangential pipe shall be carefully and neatly cut to mate upto the material applied to the parent pipe without the creation of voids or gaps, at the Junction. Insulation shall be adequately secured by wire/band of same specification as that of same size pipe.
4.2.3.6
Flanged Joints or valves (all insulation materials) (Fig 9 and 10) • Flanged Joints or Valves, if to be insulated, shall be insulated with preiabricated removable aluminium covers, lined with pipe sections/lags/slabs. • Welded valves, if insulated, shall be insulated with oversized pipe sections or lags,cut and shaped to fit around the body of the valve. Insulated valves shall be completely covered, but the insulation shall be cut and shaped around the valve stem and kept clear of the stuffing box gland.
4.2.3.7
Insulation flashing (all insulation materials): Insulation shall be stopped short of flagged Joints and unions by a sufficient distance to permit easy remova-l of the flange nuts and bolts or breaking of the unions to take place without disturbance or damage to the insulating material. At these positions the insulation shall be bevelled and sealed with a metal closure which inturn shall be sealed with waterproof sealing material.
4.2.3.8
Pipe Supports:(All Insulation materials (Fig 11)
Insulation at solid welded or clamped supports shall be cut and shaped to fit around the support and banded securely to enable the insulation to be carried with the pipe movement. When the pipe hangers pass through insulation on piping outdoors, metal hoods packed with a waterproof sealing material shall be furnished and installed. Upper bolts of the hanger clamps are not to be covered with insulation. 4.2.3.9
Steam Traced Piping ; (All insulation materials (Fig. 12) Steam traced piping and fittings shall be installed with oversized sections to allow accommodation of both parent pipe and tracer without damage or deformation of the insulation. Traced instrument line and fittings shall be totally enclosed by the insulation in a similar manner and the designed warm air annulus maintained throughout the tracer pipe length. Insulation supports for vertical pipe shall have suitable clearance for tracer pipe. Suitable putty or cement shall be used to improve the contact between pipe and tracers, throughout length of tracers.
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4.2.3.10 Electrical Traced Piping: ( Polyisocyanurate/ Cellular Glass) Electrical traced piping shall be provided with the same size insulation as would be provided if the piping were not electrically traced. 4.3 Horizontal Equipment 4.3.1 Material 4.3.1.1 Fibrous Material ( Rock or Glass wool ) Can be used for all temperatures. ShelIs:Preferably preformed Pipe or multi pipe segments or slabs cut and shaped to fit. Alternately, blanket may be accepted. Heads:Preformed blocks and slabs cut and shaped to fit. Alternatively blanket may be accepted. 4.3.1.2
Calcium Silicate, Polyisocyanurate & Cellular glass: • Can be used on all surfaces. • Temperature limitations for each shall be as per 3.2.2. • Curved segments/blocks,mitre cut' and shaped to fit.
4.3.2
Corrosion Protection before applying insulation: All Insulation Materials: For stainless steel surfaces, provide same protection as for piping per Clause 4.2.2.
4.3.3
Application (All Materials)
4.3.3.1
Following, Provided by the vessel fabricator for insulator/cladding support/securement, as indicated in enclosed sketch No 7-12-033, shall be verified for their presence by the insulation contractor, before commencing insulation work: • For vessels of diameter 2000 mm and above are provided insulation support at horizontal centre line as also vertically at tengent lines. Ring support at tangent lines are provided with 6 mm diameter holes. These are to be used for insulation securement. • At vessel heads above 600 mm outside dia meter are provided flats having 6 mm dia holes The flats are for insulaton support and holes provided in them are to be used for insulation securement.Also provided on either head is a central ring made of 10 dia galvanised steel rod. For vessels which do not have central nozzle, these rings shall not be provided by vessel fabricator. For such vessels,insulation contracter shall provide these rings. • Boot of vessel, if any. is provided with circular support ring with holes, as indicated in sketch.
4.3.3.2
Blanket shall be applied over the surface with joints tightly butted and laced together with 1mm dia galvanised lacing wire. Other block insulation
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shall be applied with the longer dimension parrallel to the axis of the vessel or equipment. When blocks are applied in multiple layers, all joints in successive layers shall be parallel to the long axis, shall be staggered and sealed with insulating cement for calcium silicate or suitable adhesive for others. In all cases, the insulation is to fit the contour of the vessel or equipment, so that the use of a levelling coat of insulating cement should not be normally necessary to get an acceptable smooth exterior. 4.3.3.3
Special considerations for insulating high temperature Vessels (Required only if provided with calcium silicate insulation) (Fig. 15) • • •
•
•
•
4.3.4
This provision is required to take care of the effects of equipment circumferential thermal expansion on insulation. This provision is required only for vesselsand exchangers provided with calcium silicateinsulation. Calcium silicate insulation should be installed in bevelled or curved segments only,to avoid voids and provide an efficient insulation system. For equipments -upto 3000 mm in diameter and 200°C, to take care of equipment circumferential expansion, the circumferential block is cut and fitted to be 13mm greater in circumference than the equipment and secured so that tension of the bands produces compression on the butt edges rather than on the surface towards the vessel; the little annular space and the compressiveness of the blocks would suffice to take care of circumferential expansion of equipment. If the vessel is above 3000 mm in diameter or if temperature is above 200°C or both, a 25mm thick Rock wool fibre blanket insulation shall be applied around the equipment prior to the application of calcium silicate. This acts as an expansion area around the equipment to act as mechanical ana sometimes thermal cushions. The calcium silicate block must be cut and fitted to the outside radius of the equipment. The insulation, when installed, should not compress the fi-brous blanket. Above provision to take care of circumferential expansion is required both for shell and head.
Insulation Securement (for all insulation materials) (Refer Fig. 13 and 14) Each layer of insulation on shells of equipment shall be secured by bands at every 225 centres. Each band shall be machine stretched and ten-sioned to remove slack only.Each layer of insulation on vessel heads shall be secured as follows: Band shall be in radial direction connecting the head central floating ring and shell girth ring. The radial bands shall be placed at not more than 150 centres for rigid and 300 for fibrous insulation, measured at the girth ring. These bands shall be machine stretched and sealed. Outermost layer of insulation shall also be supported by drawing and securing 16 SWG annealed steel wire through the 6 diameter holes provided in the shell girth ring as
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also the flats provided on heads. The wire shall be drawn through every hole and it shall be secured to the ring with a knot. 4.4
Vertical Equipment
4.4.1 Material 4.4.1.1 Fibrous material shall be same as specified for horizontal equipment. 4.4.1.2 Calcium silicate, Polyisocyanurate and cellular glass shall be same as for horizontal equipment. 4.4.2
Corrosion Protection before applying Insulation: (for all insulation material) : Corrosion prevention before applying insulation for stainless steel surfaces shall be same as specified for horizontal equipment.
4.4.3
Application (all insulation materials)(Fig 16 & 17): Application details on shell, top and bottom heads shall be similar to that of horizontal equipment. Insulation shall be laid on insulation support rings provided by the fabricator. See enclosed sketch 7-12-025.
4.4.4
Insulation Securement (all insulation materials): (Fig. 16, 17 & 18) • Bottom and Top Head insulation shall be supported by 16 SWG annealed galvanised steel wire drawn through holes in the insulation supports provided by the fabricator. • Top head insulation shall be secured by floating ring/bands provided by vessel fabricator similar to head of horizontal vessel. • Shell insulation shall be supported by bands at every 225 centres on the cylindrical portion and the bands shall be kept horizontal. Insulation Securement for Bottom head for vessel supported on legs shall be identical to that of Top head. • For insulation securement of bottom heads inside skirt no floating rings/bands need be provided; Firm securement should be ensured just by 16 SWG annealed wire drawn over insulation tightly and through the holes on support rings provided by the fabricator.
4.4.5
Expansion Joints (All insulation materials): Expansion joints shall be provided every 4000 mm (max.) The joint shall be provided at insulation support rings. It shall be a 25 mm space between the top of the insulation and the bottom of the support ring. The space shall be filled up by compressed rockwool fibre.
4.5
Flange, Nozzle, Channel Cover, Manway and Handhole flanged cover (all insulation materials): • Where insulation is required, these shall be insulated with lined removable prefabricated covers secured with t£ nds or quick release toggle clips. • Otherwise, insulation shall be stopped short of uninsulated flanges and nozzles etc, a sufficient distance to permit withdraw! of bolts without disturbing the rem index of the insulation. Insulation shall be weatherproofed and sealed at these locations.
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4.6
Irregular Surfaces such as Pumps, Compressors Turbine etc.
4.6.1
Corrosion Protection
4.6.1.1 For S.S. surfaces at all temperatures, provide same protection as indicated for piping, Clause 4.2.2. 4.6.2 Application 4.6.2.1 Fibrous Material:Material, application and insulation Securement:T his shall be Prefabricated removable aluminiumcovers,lined with mineral/wool pipe sections/lags/ slabs/mattrusses. 4.6.2.2 Calcium Silicate • Insulation material shall be insulating cement/block insulation cut and fitted. Insulation shall be applied in maximum 25 mm thick layers until the scheduled thickness is obtained. • Each layer shall be covered with a layer of 25 mm hex. 20 SWG galvanised iron wire mesh. • The final layers Shall be trovelled to a smooth finish with a 6mm thick finishing cement. • Insulation shall be bevelled back at 45° from all casing flanges, shaft seal caps and bearing boxes. 4.7
Vertical Storage Tank: (Carbon Stepl )
4.7.1 4.7.1.1
Material Polyisocyanurate : shall be foamed in-situ
4.7.1.2
Fibrous Material ( Rock /Glass wool) : Shall be in the blanket
4.7.2 4.7.2.1
Application Supporting rings/spikes (rods) for supporting insulation /cladding
form.
4.7.2.1.1 Shell :Refer Standard 7-13-003 Sh.l and 2 of 2. This Standard indicates the extent of insulation/cladding supporting/securement details provided by tank fabricator. Insulation contractor shall check for its presence before insulation application work. Following is provided by tank fabricator. • Warmer Shed :At the Junction of shell and roof, a water shed is provided to act as top covering for the shell insulation as shown in Std 7-12003. • Insulation Support will consist of 5 mm dia steel rods provided at 400 mm dia diamond pitch. Length of these lugs is 3 mm less than insulation thickness. • Cladding Support From tank top, horizontal rings shall be provided at every 1175 mm on tank shell. 4.7.2.1.2 Tank Roof :Shall be provided as per standard 7-13-003
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Insulation laying and securement
4.7.2.2
4.7.2.2.1 Shell • Application of fibrous insulation : Insulation shall be applied between rings in horizontal mode. Mattress insulation shall be applied with joints tightly butted and laced together with 1 mm dia galvanised lacing wire. Marts shall be impaled to the 5mm rod and speed washers fixed and pressed home for intimate contact of The insulation. In the case of multiple layers, speed ' washers are necessary only over the final layers, (upto and including 150 mms). Rods and speed washers of spring steel should be selected to suit each other. While rods are provided by tank fabricator, speed washers shall be furnished by insulation contractor. Insulatioji shall be further secured by bands spaced centrally between insulation supports. • Application of Polyisocyanurate :Shall be foamed in situ as per vendor's procedure (approved by NALCO) and to the satisfaction .of NALCO Site-inCharge. 4.7.2.2.2
4.8
Roof (for all materials): Application of both fibrous & polyisocyanurate shall be similar, to that as for shell. Insulation support from 5 mm dia M.S. lugs shall be exactly same as in shell.
Horton spheres;
4.8.1
Material : Shall be only mineral Rock/Glass wool blanket.
4.8.2
Application
4.8.2.1
Structural members provided by sphere fabricator for insulation/cladding securement : Insulation & Cladding supports shall be as per Standard 7-13015. Insulation laying and securement : Insulation shall be applied between rings. Mattress insulation shall be applied with joints tightly butted and laced together with 1 mm dia galvanised lacing wire.
4.8.2.2
4.8.2.3
Insulation shall be secured by drawing and securing tightly 16 SWG stainless steel wire through the 6 dia holes, provided every 200 centres,in the horizontal leg of the insulation support angle ring. The wire shall be tightly drawn over the insulation and the insulation firmly secured. The wire shall be drawn through every single individual hole and it shall be secured with angle with a knot at every fourth hole.
5.0
INSULATION FINISH
5.1
General Moisture Barrier
5.1.1
On all surfaces except horton sphere, provided Wini fibrous materials and calcium silicate : For surfaces upto 125°C, apply a breathing type moisture barrier as below. A 3 mm thick coating of mastic shall be applied to the surface of the insulation as soon as possible, after erection, to reduce the time the insulation is exposed to the weather.to a
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5.1.2
5.2 5.2.1
5.2.2 5.2.3
5.2.4
5.2.5 5.2.6
5.2.7
5.2.8
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minimum. Whilst this coat is still wet, glass cloth shall be laid over the surface and embedded in the mastic. Care shall be taken to ensure that the glass cloth is laid smooth and free from wrinkles and that no pockets of air are trapped beneath the surface. At junctions in the glass cloth, the overlap shall not be less than 75mm. A second 3mm thick coat of mastic shall be applied after approximately 12 hrs. When dry this coating shall be a minimum of 1.50 mm thick. Care must be taken, however, to ensure that the individual coats are not greater than 3mm (especially corners) otherwise some cracking of dried coat may result. The mastic shall not be applied over wet insulation or until the adhesive is dry. During the drying time, the insulation shall be protected from the weather by "Alkathene" film type tarpaulin or similar materials approved by Engineer-in-Charge. Insulation finish : The insulation finish shall provide a weatherproof-ed and mechanical damage resistant covering over the whole of the insulated areas and be applied and fitted in such a manner as to provide a close fitting assembly without gaps. Piping (For all materials) Straight pipe shall have metal jacketing cut and machine rolled, (approx. 1 metre long) wrapped around, with 50 mm minimum overlaps on both longitudinal and circumferential overlaps. All laps shall be arranged to shed water. A single bead shall be made on all overlaps to ensure tight metal to metal water tight arrangement. Self tapping screws, at every 150, shall be provided at all longitudinal overlaps for both horizontal & vertical piping. At all operating temperatures the seams at overlap positions shall be rendered watertight per clause 3.4.6 to ensure that insulation remains dry and unwetted, whether the possible water impingement is from rain, hose or fire sprinklers. The metal coverings shall be secured tightly around the insulated pipe and held in place with hands on a maximum of 300 mm centres. One band shall be located on each circumferential lap and the distance between laps divided at equal band spacings. The band securing seals shall be kept neatly in line and positioned away from viewing angles as much as is possible. Vertical overlaps on vertical or near vertical piping shall be staggered to provide overlaps at 'North' and 'South' positions in alternate sections of covering. Each section of metal coverfhg on vertical piping with insulation ttIVs larger than 250 mm shall be supported from the next lower section with two 'S' clips, fabricated from banding material. The 'S' clip shall be of sufficient length to allow the minimum overlap of 50mm. On vertical piping with O.D.'s of/600 mm and larger, the securing bands shall be supported by *J' clips, fabricated from banding material. The 'J1 clip spacing shall be a minimum of two per band.All 'J' clips shall be screwed into position and secured. Insulated bends and elbows in piping 80 mm and larger, shall be metalled with 'lobster back' segments using 10 mm minimum ball swage to assist shaping. The metal bands shall be screwed with self tapping screws and
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5.2.9 5.2.10
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metal sealants are to provided to get a completely waterproofed arrangement. Insulated bends and elbows in piping smaller than 80 mm may use complete pressed humped back flat metal elbows or fabricated 'stove pipe' elbows. The practice of locating all joints in the top portion of elevated horizontal pipes for the sake-of-good-appearance when looking up from grade shall be strongly discouraged. The joints shall be located to shed water.
5.3
Equipment (for all materials)
5.3.1
The metal jacket over vertical vessel shells shall be constructed of sheet metal panels with the weight of the pattel taken on the equipment insulation support rings, via angle brackets bolted to the pannel. Refer standard 7-12-25 for details.
5.3.2
The panels shall be applied commencing at the bottom of the vessel. Each circumferential ring of panels shall be tensioned by means of tensioning bands until the final joint is screwed tight. 'S' clips shall be used as sheeting support at unscrewed circumferential overlaps.
5.3.3
The panels shall be held tight over the vessel insulation by means of circumferential bands and sealed per 3.4.6. The bands shall be positioned on all horizontal overlaps and at 450 mm centres. Bands shall be held in their relative positions with 'J' clips and be machine stretched and sealed to remove slack only. Those bands which are not supported by 'J' clips, shall be held in position on cladding by providing poprivets every 2 metre centres
5.3.4
The panels shall have a minimum overlap of one corrugation on vertical joints and 80 mm on horizontal joints. The overlaps shall be arranged to shed water at all times.
5.3.5
The vertical and horizontal overlaps shall be secured with self tapping screws at 150 mm pitch except the horizontal overlaps pre-selected to act as expansion joints, these shall be constructed with a 150 mm overlap and shall remain unscrewed and left free to permit expansion. All overlaps shall be rendered watertight as per 3.4.6.
5.3.6
All equipment projections such as nozzles, shall have the jacketing sealed using a metal flashing, cut to fit the projection and extending above the jacket at least 80mm. The seal between the flashing and jacket shall be made watertight by use of self-tapping screws and sealing mastic.
5.3.7
Horizontal cylindrical equipment shall be furnished with flat metal jacket arranged in circumferential bands with the edge of the sheets,with the longer dimension applied around the circumference of the equipment insulation.
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5.3.8
The pariels shall have a minimum of 80 mm overlap on both longitudinal and circumferential edges, both overlaps being finished with a simple ball swage and rendered watertight as detailed in clause 3.4.6.
5.3.9
Horizontal overlaps shall be secured with No. 8x12mm long self-tapping screws set in the overlap at 150mm intervals, and shall be so arranged that staggered bands of panelling encircle the equipment. Vertical overlaps shall not be screwed for horizontal equipment.
5.3.10
The metal finish shall be banded and sealed at 450 mm centres.
5.3.11
The insulated heads of vertical and horizontal equipment shall be fabricated from flat metal,in an "Orange peel" construction with all radial seams overlapping a minimum of 50 mm and secured with self-tapping screws at 150 mm centres. All overlaps shall be ball swaged and be rendered water tight per 3.4.6.
5.3.12
Projections from the heads shall be sealed using metal flashings,neatly cut to fit around the projections and extending above the jacket for a minimum of 80 mm. The seal between flashing and jacket shall be weatherproofed with self-tapping screws and mastics.
5.3.13
Insulation at bottom heads of fully skirted eqpt. does not require weatherproofing.
5.3.14
Heads of equipments 24" O.D. and smaller shall be finished and waterproofed with square ended fabricated covers.
5.4 5.4.1
Vertical Storage Tanks Cladding Applications and Securement
5.4.1.1
Shell (Fig. 19 and Standard 7-13-003 Sh.l and 2 OF 2) • Cladding is applied over the system of horizontal rings as follows: • Overlaps in the vertical joints will be one corrugation.Overlaps in the horizontal joints shall be 50 mm (min). • Cladding to cladding fastening, at both horizontal and vertical overlaps shall be alternately by "POP" Rivets 1 self tapping screws at 150 mm pitch. • Cladding shall be secured to support ring by bolting. Bolts are provided by tank fabricator at 300 mm centres on angles provided at every 1175 centres vertically. • Cladding is secured as indicated in sketch 7-13-003. Felt washer, aluminium washer and nut shall be supplied by insulation contractor for all bolted connections at shell,roof and curb angle. Insulation shall be tu eked into the skirt . portion of the curb angle. Shell cladding and extended roof cladding shall be secured to curb angle by bolting as per sketch 7-13-003, every 1500. • Horizontal stainless steel steel bands over-cladding to be provided every 800 mm and also to coincide at every horizontal
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cladding overlaps. Bands shall be tightened, locked and lock fastened featuring stainless steel fastening 'systems. In order to prevent sliding of the bands downwards, the bands shall be secured to the cladding using POP rivets at horizontal pitch not over 2 Metres 5.4.1.2
5.5 5.5.1
: 5.5.2
5.5.3
Roof • All cladding joints shall be sealed by elasto-meric metal sealants. • Min. 75 mm overlap shall be ensured at all joints. • At all- joints, cladding to cladding securement shall be provided by self tapping screws and propi-ivots alternately, every 150 centres. • Gladding shall be secured by bolting at every 300 provided by tank fabricator. For details of cladding arrangement and bolting, see sketch 7-13-003. Horton Sphere Cladding Support • Insulation contractor shall provide 25 mm x 0.8mm S.S. Bands over insulation and instal them longitu-dinally from top to bottom of the sphere in such numbers so as to afford a maximum spacing of 1175 mm at the equator. • The S.S Bands are spanned between four floating rings, the one at the top and bottom of the sphere are provided by the sphere fabricator. • Generally the other two rings and SS bands are provided after insulation is applied prior to application of cladding. Floating rings will be constructed of 10 mm diameter rods of S.S. Diameter of ring at the top and bottom, to be provided by sphere fabricator would be around 1.2 M. • Cladding support bands shall be tightened using mechanical tighteners and fastened to MS/AS angles using two S.S. Rivets or four Nos. of Aluminium POP rivets, per angle cleat. Cladding application : While applying cladding, following shall be ensured • Min. overlaps both horizontal and vertical shall be 50 mm. Cladding Securement and Sealing of Joints • All joints to be sealed usinp elastomeric metal sealant. • Cladding to cladding securement of both vert i-cal and horizontal overlaps shall be alternately by POP rivets and self-tapping screws, at every 15 0 mm spac ing.Cladding shall be secured to the insulation angle support by bolting the cladding on the bolts provided at every 300 pitch at every angle support per standard 7-13-015. • Asbestos mill board washer, aluminium washer and nut shall be supplied by insulation contractor. • Further cladding shall be secured by 25 mm x 0.5 mm S.S. bands, applied identical to those forinsulation securement. The bands shall be provided between two floating rings, one at the top and one at the bottom and arrangement and details shall be identical to that of insulation securement.
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• Bands shall be secured to cladding every 2 M by one S.S. or two aluminium POP Rivets. While providing floating rings, for both insulation and cladding securement, following points shall be taken care of: • Floating rings shall clear nozzles/manholes etc. • Exercise extreme care while installing floating rings regarding cut outs in cladding around proj ections . • Cladding at interface between leg and the body of the sphere to be provided with care and suitably sealed to prevent water ingress.
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PIPING DESIGN DATA
1.0
THERMAL INSULATION OF PIPING, EQUIPMENT AND VESSELS
1.1
HOT Insulation Material Insulation for Heat conservation (In). Insulation for steam traced lined (It), Insulation for personal protection (Ip) The Insulation of piping, equipments and vessels shall be carried out with the following insulating material as per relevant tables of thickness for types of insulation mentioned above: Bonded mineral wool (Rockwool) Lightly resin bonded Rockwool Insulation shall conform to ASTM C592 Class II for blanket and ASTM C547 class III for preformed pipe section. Rockwool Insulation as per IS 8183 and IS 9842 are also acceptable. The material shall be suitable for intended operational temperature range from ambient to 550°C. The physical requirement of bulk density and chloride content, thermal conductivity and PH value of the material shall be as follows: Bulk densitv : 140 kg/m3 Chloride Content : 20 ppm (max.) Thermal Conductivity : 0.43mW/cm°C for mean temp. 50°C 0.52mW/cm°C for mean temp. 100°C 0.62mW/cm°C for mean temp. 150°C 0.68mW/cm°C for mean temp. 200°C 0.80mW/cm°C for mean temp. 250°C 0.90mW/cm°C for mean temp. 300°C PH Value : 7.0 to 10.0
2.0
INSULATION THICKNESS The insulation thickness and type of insulation (Ih, It & Ih) to be applied on equipments and vessels shall be as per equipment data sheet. In absence of insulation thickness on equipment data sheet pipe insulation thickness shall be followed. Insulation thickness for personnel protection (Ip) shall be 25 mm. Insulation thickness on piping shall be as per line schedule. In absence of line schedule. insulation thickness shall be as per Table-1 for Heat Conservation- Ih & It.
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3.0
WEATHER PROTECTION JACKET (CLADDING)
3.1
Aluminium jaci eting shall be used as weather protection over insulation unless otherwise specified and shall be ASTM B209 alloy 3003 H16 or IS:737 designation 31000 (Old NS3) condition H3 for flat sheets and H4 for corrugated sheets. Cladding shall be coated on the side in contact with the insulation with a bitumen anti corrosive paint. The thickness of jacket shall be as follows: For all materials except Calcium silicate * For shells of vertical vessels & columns etc. : 0.71mm (22 SWG) Corrugated * Storage tanks & tank roofs : 1.22mm (18 SWG) Flat * For horton spheres & horizontal vessels shell (22SWG) Flat and heads; vertical vessel heads. * For removable covers
: 0.71mm
: 1.22mm (18SWG) Flat
* For all piping, other than grade piping in : 0.71mm (22SWG) Flat Offsites. * For grade piping in offsites steel
: 0.56mm (24SVVG) Galvanised as per IS:277 class I or equivalent.
3.2 on.
The metal cladding shall be bent true to shape, grooved and properly screwed
3.3
To ensure perfect water proofing, all the above sheet joints shall be packed with sealing materials which may either be in the form of an elastomeric sealing compound or fibre-based bituminous felt stripes.
40
PAINTING Refer Shop and Field painting specification.
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PIPING SPECIFICATIONS FOR LIQUID PITCH SERVICE AND THERMIC FLUID
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1.0
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SCOPE:
This specification sets out the principles for the design and construction of piping network to serve liquid pitch inside the anode paste unit. The temperature of liquid pitch inside the pipe is maintained at 170 deg. C with the help of a heat transfer fluid viz bowtherm 'A' which itself is kept at a temperature of 300 deg. C.
2.0
LIQUID PITCH CIRCUIT :
2.1
MATERIAL SPECIFICATIONS :
JAKETTED PIPING: Inner pipe for liquid pitch & Jacket pipe for Servotherm-S Thermic Fluid from IOC a.
PIPES ( Inner & Jacket )
:ASTM A106 GR. B Seamless .
b.
FLANGES
:ASTM A105 , RF , ANSI CL.300 . SMOOTH FINISH.
c.
FITTINGS
:SW.'ASTM A105, ANSI CL.3000 =2") (Bends/Elbows to have a radius of 3D)
d.
VALVES
:FLGD , ASTM A216 GR. WCB, CL.300 Jacketted.
e.
GASKETS
:Spiral wound asbestos filled.
f.
BOLTING
:Fully threaded studs, ASTM A193 GR. B7 with two nuts each, ASTM A194 GR. 2H.
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2.2
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SPECIFIC CARES :
2.2.1 Liquid pitch is an abrasive material . This fact shall be taken care of while designing the piping system. 2.2.2 The outer jacket must not cover any weld . At welded joint , the outer jacket shall be interrupted and the joint by passed by a connecting pipe permitting the heai transfer fluid to flow to the next section of the jacket as shown in the sketch below.
2.2.3
All joints shall be made of materials not prone to damage by the presence of liquid pitch and Servotherm-S at their design temperatures .
2.2.4
The dimensions of the piping system carrying liquid pitch shall be designed to limit any pressure drorp to 2 bars maximum .
2.2.5
Where necessary , provision shall be made for bellow type expansion joint or any other suitable type in the jacket pipe.
2.2.6
The piping system shall be so designed that in the event of any prolonged stoppage , the lines can be gravity drained and their contents transferred , if possible , to the storage tanks .
2.2.7
The complete piping system shall be insulated with rock- wool and then covered with protective cladding
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3.0
SERVOTHERM-S CIRCUIT :
3.1 a. b. c.
MATERIAL SPECIFICATIONS : PIPES : ASTM A106 GR. B Seamless. FLANGES : ASTM A105 , RF , ANSI CL.300 , SMOOTH FINISH. FITTINGS : SW, ASTM A105 , ANSI CL. 3000 (NB. = < 1 1/2" ) BW, ASTM A234 GR. WPB , SMLS (NB. > = 2" )
d.
VALVES
e. f.
GASKETS BOLTING ,
: : :
FLGD , ASTM A216 GR. WCB , CL. 300 with stainless steel seal tight bellows. Spiral wound asbestos filled . Fully threaded studs , ASTM A193 GR. B7 with two nuts each ASTM A194 GR. 2H.
3.2
SPECIFIC CARES : All joints shall be made of materials not prone to damage by the presence of servotherm-s at its design temperature .
4.0
TESTING AND INSPECTION : All welds of liquid pitch and dowtherm circuit shall have 100% visual inspection , then first weld by the welder shall be fully radiographed and further 10% welds shall be random radiographed fully.
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SPECIAL CONDITIONS OF CONTRACT
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SPECIAL CONDITIONS OF CONTRACT 1.0
The Intent of this specification is to provide supply, construction, fabrication, erection and commissioning services for execution of projects according to most modern and proven techniques and codes. The omission of specific reference to any method and equipment or material necessary for the proper and efficient services towards installation of the Plant shall not relieve the contractor of the responsibility of providing such services, facilities to complete the project or portion of project awarded to him. The quoted rate shall deem to be inclusive of all such contingencies. All the as built drawings are to be approved by the owner prior commencement of manufacturing or construction.
1.1
It is essential that, vendors desirous of participating in the tender should visit and assess the site to have hands on requirement of the scope of work. Some of the existing components like stack which are in good condition might be used in the proposed system. However while taking decision to this effect, vendor is requested to visit site and assess the condition of the stack. The scope of work specified in this subject contract is also inclusive of stack, chimney and all allied accessories and components. The contract which is intended to be executed on LSTK basis is inclusive of all materials/ supplies/ services/ works. Cement & Reinforcement Steel Shall be issued from Nalco as Free Issue Material. Supply of water, power and compressed air as specified in the battery limit shall be provided.
1.2
It is not the intent to specify herein all details of material. Any item related to this work not covered, but necessary to complete the system will be deemed to have been included in the scope of the work. Customization required for successful completion of the project during progressive execution of the contract has to be undertaken by the vendor and shall be deemed as a part of the scope of work.
1.3
Site testing wherever required shall be carried out for all items/materials installed by the contractor to ensure proper installation and functioning in accordance with drawings, specifications and manufacturer's recommendations and instruction of the engineer/ site in-charge.
1.4
During the course of erection, testing and commissioning work certain rework/modification / rectification / repairs / fabrication etc. may be necessary on account of existing system/ already commissioned and / or units also on account of design changes and manufacturing incompatibilities and site operation / maintenance requirements. Contractor shall carryout such rework / modification / rectification / fabrication / repairs etc, promptly and expeditiously and the same shall be deemed to be part of the scope of work.
1.5
The work shall be executed in the running/ operating plant & in conjunction with numerous other operations at site. The bidder and his personnel shall
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co-operate with the existing operating setup and proceed in a manner that shall not affect the operation in anyway. 1.6
The contractor shall carry out the work in accordance with instructions/ drawings/ specification/ standard practices/ national and international norms.
1.7
Completion of work within the stipulated period is the essence of this contract.
1.8
Good quality and accurate workmanship for proper performance of equipment / systems shall be guaranteed by the vendor on every stages of supplies and works.
1.9
Preservation of all components at all stages of pre-assembly/ erection/testing and commissioning till completion of trial run of unit.
1.10
On Completion of work all the temporary buildings, structures, pipe lines, cable etc. shall be dismantled and leveled and the contractor at his cost shall remove debris as per instruction of Nalco. In the event of his failure to do so, the expenditure towards clearance of the same will be recovered from the contractor.
1.11
The Contractor shall deploy experienced Engineers, Supervisors all the skilled workmen like High Pressure Welders (gas, TIG and arc) Carbon, alloy steel welders, Gas cutters, electricians, Riggers, Serangs, rectors, carpenters, fitters etc. in addition to other skilled semi-skilled and unskilled workmen required for all the works of handling and transportation from site storage to erection site, transportation, erection, testing and commissioning contemplated under this specification. Only fully trained and competent men with previous experience of the job shall be employed. They shall hold valid certificates wherever necessary.
1.12
The contractor’s supervisory staff shall execute the work in the most substantial and workman like manner in the stipulated time. Accuracy of work, good workmanship and aesthetic finish are essential part of this contract. The contractor shall be responsible to ensure that assembly and workmanship conform to the design/ specifications/ instruction and expected level of the client/ customer.
1.13
If the contractor or his workmen or employees shall break, deface, injure or destroy any part of a building, road, kerb, fence, enclosure, water pipes, cables, drains, electric or telephone posts or wires, trees or any other property or to any part of erected components etc. The contractor shall make the same good at his own expense or in default.
1.14
The work covered under this scope of work is of highly sophisticated nature requiring best quality / proven workmanship engineering and construction management. It should also ensure successful and timely commercial operation of equipment installed. The contractor must have adequate quantity of precision tools, construction aids in possession. Contractor must
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also have adequate trained qualified and experienced supervisory staff and skilled personnel. 1.15
All the necessary certificates and licenses required to carry out this scope of work are to be arranged by the contractor then and there at no extra cost.
1.16
The contractor shall be responsible for taking all safety precautions during the construction and leaving the site safe at all times. When the work is temporarily suspended he shall protect all construction materials, equipments and facilities from causing damage to existing property interfering with the operations of the station when it goes into service. The contractor shall comply with all applicable provisions of the safety regulations clean-up programme and other precautionary measures, which the NALCO has in effect at the site.
1.17
All electrical installation covered in contractors scope are to be inspected/approved by the electrical inspector/statutory authority. Contractor is responsible for getting the Electrical inspector approval. For getting electrical inspector approval, contractor shall co ordinate with Electrical contractor. Necessary completion/test certificate for the Electrical equipments like DC systems, UPS etc covered in the contractor scope shall be arranged by the contractor.
1.18
It shall be the responsibility of the contractor to apply touch up painting on all equipment before erection. It shall be contractor’s responsibility to arrange for required labour, brush and other consumables like cotton waste, cloth etc. for carrying out preservative painting. The quoted rates shall be inclusive of above work. The contractor shall effectively protect the finished work from action of weather and from damage or defacement and shall cover the finished parts, then and there for their protection.
1.19
Provision of all types of labor, Supervisors, Engineers, watch and ward as required tools and tackles as required, consumables as required under various clauses of tender specification for handling transportation, erection, testing and commissioning.
1.20
Special Conditions of Contract shall be read in conjunction with the General Conditions of Contract, Schedule of Rates, Specification of work, Drawings and any other document forming part of this contract wherever the context so requires.
1.21
Notwithstanding the sub-divisions of the document into these separate sections and volumes, every part of each shall be deemed to be supplementary to and complementary to every other part and shall be read with and into the contract so far as it may be practicable to do so.
1.22
Where any portion of the Special Conditions of Contract is repugnant to or at variance with any provisions of the General Conditions of Contract, then unless a different intention appears, the provision of the Special Conditions of Contract shall be deemed to override the provision of the General Conditions of Contract only to the extent such repugnancies or variations in
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the Special Conditions of Contract as are not possible of being reconciled with the provision of General Conditions of Contract. 1.23
The materials, design and workmanship shall satisfy the standards, specifications contained herein and codes referred to. Technical Specifications stipulate requirements in addition contained in the Standard Codes and Specifications, those requirements shall also be satisfied.
1.24
Wherever it is mentioned in the specifications that the Contract shall perform certain work or provide certain facilities, it is understood that the Contractor shall do so at his own cost and the Contract Price shall be deemed to have included cost of such performances and provisions, so mentioned.
1.25
Completion Time: The entire contract both supply & works shall be completed within 6-8 months from the date of placement of order. The placement of fax of intent shall be treated as zero date of the project.
1.26
The bidder shall furnish project completion schedule indicating major milestones along with the quotation.
1.27
The time schedule should be in the form of PERT network considering the date of issue of Fax of intent as the zero date and should show completion of various events/activities there from.
1.28
The effective date of contract/time of commencement shall be the date of issue of Fax of Intent or Letter of Acceptance whichever is earlier.
1.29
The successful tenderer shall submit a Master Network within three weeks from date of issue of Fax of Intent. The master network will be in the form of PERT/CPM NETWORK prepared system wise containing major milestones in all phases of execution of contract. Each event/activity will also have earliest completion date, latest completion date and float in number of days/weeks. The final master network as mutually agreed upon would form the basic document from which schedules for design, engineering, procurement, construction and commissioning will be arrived at. These schedules will be prepared discipline or system wise. The final master network shall also form the basis for review of schedules, short-term programme and progress reporting for the entire run of the contract. The frequency/periodicity of programming and reporting will be mutually agreed upon. Progress reporting shall be done by the Contractor on mutually agreed formats. Reports on such formats will be sent regularly to the Engineer-inCharge in reproducible with six copies of print as per frequency/periodicity agreed upon from time to time.
1.30
The contractor shall arrange for weekly progress review meeting with the “Engineers” at site during which actual progress during the week vis-à-vis scheduled programme shall be discussed for action to be taken for achieving targets. The programme for subsequent work shall also be presented by contractor for discussion. The contractor shall constantly update/revise his
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work programme to meet the overall requirements and suit the material availability. 1.31
The Contractor shall have independent account codes from concerned Regional Provident Fund Commissioner for Provident Fund and Independent account code from Regional Director ESI for ESI. Fulfilling all statutory stipulations towards PF & ESI is mandatory for the bidders.
1.32
Before starting of work, the Contractor shall obtain a license from the concerned authorities under the Contract Labour (Abolition and Regulation) Act 1970, and furnish copy of the same to the Owner.
1.33
Contractor shall observe all Codes specified in respective specification, all national and local laws, ordinances, rules and regulations and requirements pertaining to the work and shall be responsible to fulfill all such norms.
1.34
Contractor shall have at all times during performance of the work, post a technically competent person to supervise the work at the work premises. Any instruction given to such a person by the Owner/ Engineer in charge shall be construed as having been given to the Contractor.
1.35
Owner reserves the right to inspect all phases of Contractor’s operations to ensure conformity to the specifications. Owner will have engineers, inspectors or other duly authorized representatives, made known to the Contractor, present during progress of the work and such representatives shall have free access to the work at all times. The presence or absence of an Owner’s representative does not relieve the Contractor of the responsibility for quality control in all phases of the work. In the event that any of the work being done by the Contractor is found by Owner’s representatives to be unsatisfactory or not in accordance with the drawings, procedures and specifications, the Contractor shall, upon verbal notice of such discrepancy or deficiency, take immediate steps to revise the work in a manner to conform to the relevant drawings, procedures and specifications.
1.36
The Contractor shall carry out required supervision and inspection as per Quality Assurance Plan and furnish all assistance required by the OWNER in carrying out inspection work during this phase. The owner will have engineers, inspectors or other authorized representatives present who are to have free access to the work at all time. If an Owner’s representative notifies the Contractor’s authorized representative of any deficiency, or recommends action regarding compliance with the specifications, the Contractor shall make every effort to carry out such instructions to complete the work conforming to the specifications and approved drawings in the fullest degree consistent with best industry practice.
1.37
For all payment purposes, measurement will be based on the execution drawings. Wherever details are inadequate or not available in the execution drawings, physical measurements will be taken by the contractor in the presence of the representative of the Engineer-in-Charge. In such cases, payment will be made on actual measurements.
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Payment terms: For Supply Portion : a) 70 % against proof of supply b) 20 % after Installation & commissioning c) 10 % against submission of BG amounting to 10 % of the total supply value For Works Portion: a) 80 % against progressive submission of RA Bill b) 10 % after Installation & commissioning c) 10 % against submission of BG amounting to 10 % of the works value
1.18 The Contractor shall without prejudice to his overall responsibility to execute and complete the works as per specifications and time schedule progressively deploy adequate qualified and experienced personnel together with skilled/unskilled manpower and augment the same as decided by Engineer-inCharge depending on the exigencies of work to suit the construction schedule without any additional cost to Owner. The works under this contract are to be carried out in areas declared as plant limits, adjacent / adjoining to the existing operating plant. As such, Contractor is required to abide by all safety and security regulations of the Owner enforced from time to time. 1.19 The Contractor has to apply for photo entry passes for his workers & staff in a prescribed proforma available with Owner for persons requiring entry in to Plant premises as required. Identity card issued by the Security Section should always be carried/ displayed by the Contractor’s employee or person while working inside the Plant. Permits are to be obtained separately for use of vehicles/ trailers etc. at work site. The following requirements are to be met to obtain vehicle permit: 1.20 To bring materials/ equipment/ tools/ tackles etc., to Construction site the work, the Contractor has to produce challan/ proper documents to the Owner’s personnel at gate. The materials shall be checked thoroughly by the Owner’s personnel at Gate and recorded in their register before allowing any materials to the site. It is Contractor’s responsibility to see that the recorded entry No., date, signature of Owner’s authorized representative with stamp are there on the challan/ supporting documents before taking any materials into work site. In addition to above, entry of the material will be permitted only during the stipulated working hour, and more so, if consignee is available to receive the said material. 1.21 The work shall be carried out inside the plant as per safety practices enforced by NALCO safety section and instructions of Engineer-in-charge issued from time to time. Many times it may happen that the working hours shall be drastically reduced or increased to meet certain safety requirements and the
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Contractor shall meet these requirements without any argument for time and financial implications. To obtain work permit and to satisfy all conditions laid down therein, shall be the responsibility of the Contractor. No claim for idling of machinery, plant, manpower etc., for safety reasons or non-issuance of work permit by In-charge, Safety Section shall be considered. The Contractor shall abide by all safety regulations of the plant and ensure that safety equipment or specific job kit as stipulated in the Factory Act / Safety Hand Book is issued to the employee during the execution of work, failing which all the works at site will be suspended. 1.22 NALCO being an ISO 14000 Company, the Contractor shall comply with all the provisions of ISO 14000 (EMS Criteria) for proper disposal of debris, unused oils, lubricants etc. in consultation with Engineer-in-Charge. The contractor shall also abide by other stipulations of ISO 14000 as laid down by the said system. The Contractor shall from time to time clear and remove all rubbish and constructions, equipment, unused materials, etc. resulting in the execution of the work. The disposal of rubbish will have to be done only in the areas earmarked by the Owner as per the direction of the Engineer-in-Charge. All streets and driveways in the work area shall be kept clear and unobstructed at all times. Working site should be always kept cleaned up to the entire satisfaction of Engineer-in-Charge. Before handing over of any work to Owner, the Contractor in addition to other formalities to be observed as detailed in the document shall clear the site to the entire satisfaction of Engineer-in-Charge. 1.23 Construction shall be as per drawings/specifications issued/approved by Engineer-in-Charge issued from time to time during the course of execution of work. The quoted rates shall be deemed to include cost of preparation and submission of fabrication drawings (if any) for review and approval of Engineerin-Charge. It is however, clearly agreed by the Contractor that review and approval of the drawings by Engineer-in-Charge shall not absolve the Contractor of his responsibility to carry out the work as per specifications. 1.24 All inspection and test on bought out items if any shall be made as required by specifications forming part of this contract. Various stages of inspection and testing shall be identified after receipt of Quality Assurance Programme from the Contractor / manufacturer. Inspection calls shall be given for association of OWNER/ ENGINEER IN CHARGE as per mutually agreed programme in prescribed proforma with 15 days margin, giving details of equipment and attaching relevant test certificates and internal inspection report of the Contractor. All drawings, general arrangement and other contract drawings, specifications, catalogues etc., pertaining to equipment offered for inspection shall be got approved by OWNER/ ENGINEER IN CHARGE and copies shall be made available to OWNER / ENGINEER IN CHARGE before hand for undertaking inspection. The Contractor shall ensure full and free access to the inspection engineer of OWNER/ ENGINEER IN CHARGE at the Contractor or their sub-Contractor’s premises at any time during contract period to facilitate him to carry out inspection and testing assignments.
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The Contractor shall provide all instruments, tools, necessary testing and other inspection facilities to inspection engineer of OWNER/ ENGINEER IN CHARGE free of cost for carrying out inspection. Where facilities for testing do not exist in the Contractor’s laboratories, samples and test pieces shall be drawn by the Contractor in the presence of Inspection Engineer of OWNER / ENGINEER IN CHARGE and duly sealed by the letter and sent for tests in Government approved Test House or any other testing laboratories approved by the inspection Engineer at the Contractor’s cost. The Contractor shall comply with the instructions of the Inspection Engineer fully and with promptitude. The Contractor shall ensure that the equipment / assemblies / component of the plant and equipment required to be inspected are not assembled and despatched before inspection. The Contractor shall ensure that the parts once rejected by the Inspection Engineer are not used in the manufacture of the plant and equipment. Where parts rejected by the Inspection Engineer have been rectified or altered, such parts shall be segregated for separate inspection and approval, before being used in the work. On satisfactory completion of final inspection and testing, all accepted plant and equipment shall be stamped suitably and inspection Certificate shall be issued in requisite copies for all accepted items. For stage inspection and for rejected items, only inspection memo shall be issued indicating therein the details of observations and remarks. The Contractor shall carry out the various tests as enumerated in the technical specifications of the Tender Document and the technical documents that will be furnished to him during the performance the works and no separate payment shall be made unless otherwise specified. The nature of testing to be done, periodical intervals at which such testing are to be done, etc. as per the latest editions of relevant IS codes shall be determined by the Engineer-in-Charge. 1.25 The work is subject to inspection at all times by the Engineer-in-Charge. The Contractor shall carry out all instructions given during inspection and shall ensure that the work is being carried out according to the technical specifications of this tender, the technical documents and the relevant codes of practice furnished to him during the performance of the work. The Contractor shall provide for purposes of inspection access ladders, lighting and necessary instruments at his own cost for inspection of work Any work not conforming to the execution drawings, specifications or codes shall be rejected forthwith and the Contractor shall carry out the rectification at his own cost. All results of inspection and tests will be recorded in the inspection reports, proforma of which will be approved by the Engineer-in-Charge. These reports shall be part of the completion documents. 1.26 Inspection and acceptance of the work shall not relieve the Contractor from any of his responsibilities under this contract. 1.27 After completion of all tests as per specification the whole work will be subject to a final inspection to ensure that job has been completed as per requirement. If any defects noticed in the work are attributable to Contractor, these shall be attended by the Contractor at his own cost as and when they are
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brought to his notice by the Owner. The Owner shall have the right to have these defects rectified at the risk and cost of the Contractor if he fails to attend to these defects immediately. 1.28 It shall be entirely the Contractor’s responsibility to provide, operate and maintain all necessary construction equipment, scaffoldings and safety gadgets, cranes and other lifting tackles, tools and appliances to perform the work in a workmanlike and efficient manner and complete all the jobs as per time schedule. 1.29 Bidder shall include in his offer the Quality Assurance Programme containing the over all quality management and procedures which is required to be adhered to during the execution of contract. After the award of the contract, detailed quality assurance programme shall be prepared by the Contractor for the execution of contract for various works, which will be mutually discussed and agreed to. The Contractor shall establish document and maintain an effective quality assurance system. The Owner/ Consultant or their representative reserve the right to inspect / witness, review any or all stages of work at shop / site as deemed necessary for quality assurance. 1.30 Drains, pipes, cables, overhead wires and similar services encountered in the course of the works shall be guarded from injury by the Contractor at his own cost, so that they may continue in full and uninterrupted use to the satisfaction of the Owners thereof, or otherwise occupy any part of the site in a manner likely to hinder the operation of such services. Should any damage be done by the Contractor to any mains, pipes, cables or lines (whether above or below ground etc.), whether or not shown on the drawings the Contractor shall make good or bear the cost of making good the same without delay to the satisfaction of the Engineer-in-charge. 1.31 When applicable, the Contractor shall engage a renowned electrical contractor for executing the electrical work and before arranging electrical contractor, the Contractor shall take approval from the Engineer-in-Charge for the same. Proper coordination with electrical agencies will be the civil contractor’s responsibility. Where embedding of conduits in concrete slabs, walls etc. is involved, the Contractor shall ensure that the work of civil and other works shall not be held due to non-completion of the part of electrical work. In case of any dispute the decision of the Engineer-in-Charge shall be final and binding on the Contractor. The application on behalf of the Owner for submission to Electrical Inspector along with the copies of required certificates complete in all respects shall be prepared by the Contractor and submitted to Engineer-in-Charge for onward transmission well ahead of time so that the actual commissioning of Electrical Work is not delayed for want of inspection by the Inspector. The actual Inspection of work by the Electrical Inspector shall be arranged by the Contractor and necessary coordination and liaison work in this respect shall be the responsibility of the Contractor. However, any fee paid to the Electrical Inspector in this regard shall be reimbursed by the Owner on production of documentary evidence. 1.32 While selection of the technology, equipment, and process vendor has to ensure that, latest technology & engineering practices are followed and
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complied with emphasis of safety, statutory & regulatory requirements as specified in national & international standard. 1.33 All design basis, calculations, drawings, layout, & specifications etc. are to be ratified/ verified by the vendor. If required, all documents are to be approved by Nalco prior to use. 1.34 Vendor to ensure full compatibility of the proposed system with the existing layout/ system & processes. 1.35 While preparing PDS/ selection of the equipments, protection, enclosures, safety devices, drives etc.; emphasis has to be laid down on existing site conditions and operational practices. 1.36 Since the project has to be constructed in the vicinity of operating plant, vendor executing the project has to cushion unavoidable delays on account of operational constraints in construction/ commissioning activities. Such assessment is to be assessed prior commencement of the project. 1.37 Appropriate provision of access points like walkway, staircase, ladders etc. for operational and maintenance convenience are to be suitable incorporated in the detailed engineering. 1.38 All rotating equipments shall have vibration limits as specified in IS: 14817:2000. 1.39 Drive motor selected for the system/ process shall be of energy efficient type. 1.40 All correspondence, submission of Bills, Data sheet, documents shall be marked to the designated project coordinator. 1.41 Compliance to statutory & regulatory requirements during consecution and erection shall be the scope of EPCC contractor. 1.42 In the event of non-availability of data or information related to the project, consultant/ EPCC vendor has to collect actual date from site. Nalco will facilitate providing data depending upon the availability at our archives or site. 1.43 The vendor shall specify the manner for movement/ storage of construction material for the EPCC contractor so that normal operating plant is not affected. 1.44 Provision of customer support training has to be reflected while preparation of detailed engineering. Training requirements such as schedule, programme content and other relevant information has to be brought out as soon as the commissioning of the plant is over. 1.45 Unless and otherwise specified, equipment/ system design shall emphasis on energy saving practices and compatible to national and international standard.
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SPECIAL INSTRUCTIONS TO BIDDERS 1.0 Single party executing the project from concept to completion on turnkey basis covering all aspects of the project is required for successful implementation of the project. 2.0 Technology: System, process, equipments, components selected for this turnkey project shall be based on latest & proven and technology acclaimed nationally and internationally. 3.0 Bidders participating in this tender shall have adequate experience in executing similar turnkey project in liquid storage & handling especially bituminous products and its derivatives with provision of heat circulating thermic fluid, bulk storage of liquids, turnkey projects in storage tank & pressure vessels. The turnkey shall include conceptualization of the requirement, engineering, designing, manufacturing, supply, construction, erection, commissioning & testing. Details of project completed with scope of work, value, period of completion, year of completion and other details shall be furnished along with the tender documents. 4.0 The Bidder must submit their bids as requested in a sealed cover prominently super scribing the Tender Specification number, due date and time of submission as mentioned in the TENDER NOTICE. The following information shall be furnished by the Bidder along with their offer (Technical Bid cover) 5.0 Details of previous experience during the last five years indicating contract value, duration, completion period and present engagement. 6.0 Financial status of the firm enclosing balance sheet and profit and loss account for the past 3 years and certificate from the Company’s Banker. Turnover of the Company in last 3 financial years pertaining to this scope of work only. 7.0 BIO DATA of key personnel presently in the Rolls of the company and proposed site organization for carrying out the work including deployment of Engineers and Supervisors. 8.0 THE BIDDERS ARE REQUESTED TO FURNISH THE DOCUMENTS LIKE COPIES OF LOI’S, WORK ORDER’S ETC PERTAINING TO THE EXPERIENCE INDICATED IN QUALIFYING REQUIREMENTS.
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